Model 7000 Manual

Pick and Place Handler Model 7000-BPR User Manual
Version 1.0 January 10, 2011

Based on Print 700-421-1
Exatron, Inc.
2842 Aiello Drive San Jose, California 95111 (408) 629-7600 Tel (800) exa-tron Tel (408) 629-2832 Fax www.exatron.com
Copyright Notice
Copyright 2011 Exatron This document contains proprietary information which is protected by copyright. All rights are reserved. EXATRON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The information contained in this document is subject to change without notice.
Table of Contents
List of Figures Chapter 1: Safety, Support and Options
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Exatron Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Lock-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Facilities Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Air Conditioning and Environmental Requirements . . . . . . . . . . . . . . . . . 1-4 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Vacuum/Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Uncrating the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Mounting the Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Customer In-House Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Offshore Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Exatron Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Warranty and Support Contracts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Service Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Preventive Maintenance Contract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Customer Service Support Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 End-of-Life Handler Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Significance of This Manuals Version Number. . . . . . . . . . . . . . . . . . . . . . 1-21 Typographical Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 1-22 Terms Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Chapter 2: System Description

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 How the System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Modes of Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Pickup Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Lead Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Sort Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Anti-Vibration Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
-- continued on next page --
01/2011
Copyright Exatron, 2011
Contents-1
Model 7000-BPR Manual
Chapter 2: System Description continued

Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Main Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 HALT and RUN Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Carrier Solenoids on Output Sort Wheel . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Pneumatic Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Pickup Head Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Main and Auxiliary Air Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Vacuum Generator with Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Bowl Feeder Air Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Tape-and-Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Override Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 CE Marking Standard Practice and Options . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Chapter 3: Hardware and Software Setup

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Setting Up Your New Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Leveling Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Changeover Kits for Various Device Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Powering Up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Shutting Down the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Setting Up a Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Mounting a Takeup Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Mounting a Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Replacing the Tape Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Loading the Carrier Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Loading the Sealing Tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Adjusting Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Understanding Blade Sizes and Orientation . . . . . . . . . . . . . . . . . . 3-18 Changing Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Adjusting Seal Heads Lateral Position . . . . . . . . . . . . . . . . . . . . . . 3-21 Adjusting Seal Heads Downward Pressure . . . . . . . . . . . . . . . . . . 3-23 Adjusting Speed of Seal Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Setting Temperature for Heat Seal Head . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Getting Acquainted with the Main Window . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Contents-2
01/2011
Chapter 3: Hardware and Software Setup continued

Verifying the Factory-Installed Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Copying the Job File for Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Opening a Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Fine Tuning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Saving the Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Changing the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Chapter 4: Diagnostics
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Keeping Your Original Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Diagnostics Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 USB Sensor/Solenoid Check Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Input Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Output Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Features on All I/O Pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Selecting a Board to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Board 1Output Sort Wheel Carrier Positions . . . . . . . . . . . . . . . . . . . . 4-6 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Board 2Motor Home and Present Sensors . . . . . . . . . . . . . . . . . . . . . . 4-7 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Board 3Z Pickup Nozzles Vacuum and Blow-Offs . . . . . . . . . . . . . . . . 4-8 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Motor Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Motor List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Home Sequence Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Sensor/Solenoid Check Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Loading an Inspection File to the Camera . . . . . . . . . . . . . . . . . . . . . . . 4-15 Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Fine Tune Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Sort Wheel Motor Position Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Pickup Wheel Motor Position Group Box . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Messages and Motors Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Inspection Job Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Increment Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
01/2011
Contents-3
Chapter 4: Diagnostics continued

Fine Tune Window continued Dead Nest Air/Vac Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Pickup Wheel Motor Offset Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Sort Wheel Motor Offset Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Comparing the Z Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Pick Motor Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 I/O Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Drop to Carry Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Tape Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Taper Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Test Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Seal Head Temperature Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Tape Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Taper Empty Pocket Latch Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Chapter 5: Auto Run

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Halt, Run, and EMO Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Starting an Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Auto Run Using Tape and Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Auto Run Window Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Statistics Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Auto Run Status Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Tester Operation Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Start Time Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Chapter 6: Resistor Tester

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Starting the Tester Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Switching Between System Computers . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Testing Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Accessing a Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Contents-4
01/2011
Chapter 6: Resistor Tester continued

Single-Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Batch Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Output Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Status Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Example Test Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Multiple-Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Batch Group Boxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Totals Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Chapter 7: Bowl Feeder

Document Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Vibrator Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Vibrator with Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Vibrator with Programmable Controls . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Air Jets and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Bowl Feeder Changeover Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Emptying the Bowl Feeder of Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Removing Bowl Feeder Changeover Parts . . . . . . . . . . . . . . . . . . . . . . 7-11 Installing Bowl Feeder Changeover Parts . . . . . . . . . . . . . . . . . . . . . . . 7-13 Troubleshooting Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Chapter 8: Servicing and Troubleshooting

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Backing Up the Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Cleaning the Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Cleaning or Replacing the Suction Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lubricating the Bearing Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Checking Lead Screw/Coupling Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Master and Slave Cool Muscle Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Setting Up a Cool Muscle Motor Controller . . . . . . . . . . . . . . . . . . . . . . . 8-7 Replacing a Cool Muscle Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Programming a Cool Muscle Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Checking Motor Serial Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
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Chapter 8: Servicing and Troubleshooting continued

Air Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Checking Incoming Air from the House Supply . . . . . . . . . . . . . . . . . . . 8-18 Checking the Moisture/Dirt Trap in the Air Regulator . . . . . . . . . . . . . . . 8-18 Checking the Air Regulator Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . 8-21 Adjusting Air Pressure on the Regulator. . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Adjusting Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Adjusting Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 Vacuum Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Troubleshooting Vacuum Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Vacuum Generators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Vacuum Switches Used with Vacuum Pump . . . . . . . . . . . . . . . . . . 8-28 Checking and Replacing a Vacuum Air Filter . . . . . . . . . . . . . . . . . . . . . 8-28 Adjusting Pickup Nozzle Blow-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 Adjusting Blow-Off for Handler Using In-House Air Supply . . . . . . . 8-30 Adjusting Blow-Off for Handler Using Vacuum Pump Air Supply . . 8-30 Cleaning Vacuum Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Checking and Setting the Vacuum Generator . . . . . . . . . . . . . . . . . . . . 8-36 Solenoid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 Opening the Computer for Part Replacement . . . . . . . . . . . . . . . . . . . . . . . 8-44 Fiberoptic Photoelectric Sensor Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 8-48 Taper Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49 Laser Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50 Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50 Setting LAN Connections and Required IP Addresses. . . . . . . . . . . . . . 8-50 Testing Network Communication with Peripherals . . . . . . . . . . . . . . . . . 8-56 Remote Handler Control with WebEx . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59 Replacing Exatron Program File with an Upgrade . . . . . . . . . . . . . . . . . . . 8-61 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64 Motors Move Very Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64 System Does Not Pick Up Devices Reliably. . . . . . . . . . . . . . . . . . . . . . 8-64
Chapter 9: Parts List

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Suction Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Vacuum Generator Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Z Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Hose Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
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Chapter 9: Parts List continued

Guide to the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Exatron (Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Part Quantity Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Chapter 10: Prints

List of Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 How to View the Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Appendix A: Test Interfaces

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Components of Test Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 DUT InterfaceHardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Control InterfaceMethod of Communication . . . . . . . . . . . . . . . . . . . . . A-2 TCP/IP Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 TTL Handler Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Start Test Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Sort Test Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 End of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Handler Port Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Handler Port Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Serial Port Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Exatron RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Beginning the Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Starting the Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 After the Test Is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Cycle Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Exatron Plus RS-232 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Command Set Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 Serial Commands for Multiple Test Sites with One Serial Port . . . . . . . . . . A-17 Command Set Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17 Multiple Sockets in Multiple Sites. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18 Request for Tester Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19 GPIB Test Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 If the Tester Controls the Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 If the Handler Controls the Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
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Appendix A: Test Interfaces continued

Decimal-Hexadecimal-Binary-ASCII Conversion Table . . . . . . . . . . . . . . . A-23 Setting Up HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 Configuring a Connection Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 Testing Communication Between Handler and Tester . . . . . . . . . . . . . . A-29
Appendix B: System Backup and Recovery

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Setting a Computer to Boot from CD-ROM . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Creating a Secure Zone on the Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Backing Up a Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15 Copying Archive Files to CDs or DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28 Restoring a Disk or Partition Backup from CD-ROM. . . . . . . . . . . . . . . . . . B-28 Restoring a Backup Under Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-40
Index
Contents-8
01/2011
List of Figures
Figure 1-1: EMO (Emergency Stop) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-3: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-4: Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Figure 1-5: Drop-Down Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Figure 1-6: Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Figure 1-7: Input Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Figure 2-1: Handlers Input Side with Bowl Feeder and Test Site . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Figure 2-2: Handlers Output Side with Sort Wheel and Taper . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Figure 2-3: Simplified Diagram of Major Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2-4: Pusher Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-5: Pickup Wheel Rotary Motor (Left); Sort Wheel Rotary Motor (Right) . . . . . . . . . . . Figure 2-6: Rotary Motor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-7: Pickup HeadsOver Test Site (Left), Over Taper (Right) . . . . . . . . . . . . . . . . . . . . Figure 2-8: Lead Screw on Pusher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2-5 2-5 2-6 2-6
Figure 2-9: Sort BucketsTop View (Left); Front View (Right) . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-10: Anti-Vibration FootTop (Left), Bottom (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-11: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-12: Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-13: 24-Volt DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-14: CPU Power Supply Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-15: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input . . Figure 2-16: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-17: Serial Hub or Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-18: Output Sort Wheel with 16 Carriers and 8 Buckets . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-19: Carrier Gate Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-20: Carrier Gate Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-21: Auxiliary Air Regulator on Left; Main Air Regulator on Right. . . . . . . . . . . . . . . Figure 2-22: Vacuum Generator for Each Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-23: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-11 2-12 2-13 2-13 2-14 2-14 2-15 2-16 2-17
Figure 2-24: Air Valves on Manifold Block (Left); Colored Air Hoses to Bowl Feeder Air Jets (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Figure 2-25: Reels on Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
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Figures-1
Figure 2-26: Tape Track with Sensors and Pickup Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure 2-27: Pressure Roller Block, Seal Head, and Image Sensor . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure 2-28: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right) . . . . 2-20 Figure 2-29: Other Features of Taper (Model 201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-30: Taper Override Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-31: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-32: Gold Alodine Finish on Interior Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2-33: Ferrite EMI Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 2-22 2-23 2-23 2-24 3-2 3-2 3-4 3-5 3-6 3-6 3-7 3-8 3-9 3-9
Figure 3-1: Wheel Unlocked (Left), Locked (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-2: Anti-Vibration Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-3: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Powering Up the Handlers Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: Shutting Down Windows from the Start Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-6: Selecting the Turn Off Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-7: Model 202 Fixed-Width Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-8: Locking Hub on Takeup Reel with Alignment Pins. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-9: Center Prongs of Supply Reel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-10: Changeover Tape Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-11: Screws on Side of Tape Track to Be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-12: Cover Tape Guide Block Assembly Pushed Left . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-13: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-14: Carrier Tape Under Guide At Bottom Rear of Track . . . . . . . . . . . . . . . . . . . . . . . Figure 3-15: Carrier Tape Under Guide At Top Front of Track . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-16: Lifting Pressure Roller Arm and Pushing In Keeper Pin . . . . . . . . . . . . . . . . . . . . Figure 3-17: Tape Under Takeup Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-18: Sealing Tape PlatesOutside (Left), Inside (Right) . . . . . . . . . . . . . . . . . . . . . . . Figure 3-19: Adjustment Collar on Sealing Tape Supply Reel . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-20: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-21: Two Widths of Guide BlocksTop View (Left); Bottom View (Right). . . . . . . . Figure 3-22: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-23: Guide Block Partly Removed from Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-24: Guide Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-25: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom . . . . . . . . . . . . .
3-10 3-11 3-11 3-12 3-13 3-13 3-14 3-14 3-15 3-15 3-16 3-16 3-17 3-17 3-18
Figure 3-26: Top Side of Blades As They Slide into Seal Head (Left); Bottom Side of Blades That Contact Tape (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Figure 3-27: Replacing Heat Seal Head Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
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List of Figures
Figure 3-28: Seal Head with Empty Rails for Blade Insertion (Back View) . . . . . . . . . . . . . . . 3-20 Figure 3-29: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Figure 3-30: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Figure 3-31: Example of Good Tape Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-32: Auxiliary Air Regulator for Seal Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-33: Outward-Facing Knob Adjusts Upward Speed; Right Knob Adjusts Downward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-34: Heater Controller Displaysin Celsius (Left), in Fahrenheit (Right) . . . . . . . . . . Figure 3-35: Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3-23 3-24 3-25 3-26
Figure 3-36: Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Figure 3-37: Opening a Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Figure 3-38: Changing Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Figure 4-1: Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Figure 4-2: Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3: Opening a Job File for Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-4: Buttons on Each Diagnostic Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-5: Test Rotary Motor and I/O Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-6: Port Selection Drop-Down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-7: USB Sensor/Solenoid Check WindowBoard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4-3 4-5 4-6 4-6
Figure 4-8: USB Sensor/Solenoid Check WindowBoard 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 4-9: USB Sensor/Solenoid Check WindowBoard 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Figure 4-10: Motor Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Figure 4-11: Motor List Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 4-12: Motor Settings Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 4-13: Home Sequence Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-14: Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-15: Sensor/Solenoid Check Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-16: Bit Settings for Inspection Files 1005, 1206, and 1505 . . . . . . . . . . . . . . . . . . . . . Figure 4-17: Bit Settings for Inspection Files 2010 and 2512. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-18: Taper Control Panel with Sensor Lights and Override Buttons . . . . . . . . . . . . . . . Figure 4-19: Taper with Image Sensor (Left) and Gap Sensor (Right). . . . . . . . . . . . . . . . . . . . Figure 4-20: Fine Tune Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-21: Sort Wheel Motor Position Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-22: Pickup Wheel Motor Position Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-23: Messages and Motors Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-24: Inspection Job Drop-Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-25: Dead Nest Air/Vac Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-26: Delay Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-12 4-14 4-16 4-17 4-18 4-18 4-19 4-20 4-21 4-22 4-23 4-23 4-24
01/2011
Figures-3
Figure 4-27: Pickup Wheel at Home Position (Left); Moved to Offset (Right) . . . . . . . . . . . . . 4-25 Figure 4-28: Pickup Wheel Motor Offset Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-29: Sort Wheel Motor Offset Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-30: Suction Cup at Z-Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-31: Suction Cup at Z-Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-32: Pick Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-33: I/O Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-34: Test Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-35: Drop to Carry Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-36: Tape Motor Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-37: Taper Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-38: Test Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-39: Seal Head Temperature Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-40: Motor Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-41: Tape Reel Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-42: Gap Sensor Offset from Pickup Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 4-26 4-27 4-27 4-28 4-29 4-30 4-31 4-32 4-34 4-34 4-35 4-36 4-37 4-38
Figure 4-43: Leader Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Figure 4-44: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right) . . . . . 4-40 Figure 4-45: Counting Number of Sprocket Holes Between Pocket Centers . . . . . . . . . . . . . . . 4-40 Figure 5-1: HALT, RUN, and EMO (Emergency Stop) Buttons . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Figure 5-2: Opening a Job File for Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Figure 5-3: Auto Run Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-4: Bucket Setting Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-5: Initializing Taper Before Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-6: Advance Trailer Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-7: Statistics Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-8: Auto Run Status Group Box with Full Messages Turned On. . . . . . . . . . . . . . . . . . . Figure 5-9: Tester Operation Group Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-1: Tester Main Window Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-2: Load Job File Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-3: Auto Run Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-4: Output Group Box with Pass Drop-Down Selections . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-5: Binning of Each Test Result Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-6: Testing Multiple Values Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-7: Batch Group Box (Left); Pass Output Bin Selections Drop-Down (Right) . . . . . . . . Figure 6-8: Totals Group Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5-4 5-5 5-7 5-8 5-9 5-9 6-2 6-3 6-4 6-5 6-7 6-8 6-9 6-9
Figure 7-1: Bowl Feeder Viewed from Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Figure 7-2: Rodix Feeder Cube Dual-Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Figures-4
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List of Figures
Figure 7-3: Rodix Feeder Cube Single-Control BoxTwo Versions . . . . . . . . . . . . . . . . . . . . . 7-3 Figure 7-4: Rodix Feeder Cube with Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Figure 7-5: Both types of Feeder Cubes Used Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Figure 7-6: Air Jets 1 and 2 with Sensor (Left); Air Jets 3 and 4 with Sensor (Right) . . . . . . . . . Figure 7-7: Air Tubes with Air Flow Controls and Sensor Controllers (Left); Air Flow Control Close-up (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-8: Bowl Sensor at Inline Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-9: Various Sizes of Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-10: Bowl Feeder Changeover Kit Tooling Fastened to Storage Plate . . . . . . . . . . . . . . 7-5 7-6 7-6 7-7 7-7
Figure 7-11: Holding Devices Above Comeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Figure 7-12: Masking Tape Guiding Devices Out the Comeout. . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Figure 7-13: Unscrewing and Opening Comeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Figure 7-14: Devices Falling from Comeout into Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Figure 7-15: Dead Nest Stop on Dead Nest (Left); Dead Nest with Stop Removed (Right) . . . 7-11 Figure 7-16: Dead Nest Removed from Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-17: Inline Track with Top Confinement (Left); with Top Confinement Removed (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-18: Discharge with Top Confinement (Left); with Top Confinement Removed (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7-19: Discharge Without Top Confinement (Left); With Top Confinement (Right) . . . Figure 7-20: Inline Track Top Confinementby Inline (Left), Fitted on Inline with Device Slot at Left (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 7-12 7-12 7-13 7-13
Figure 7-21: Alignment Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Figure 7-22: Dead Nest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Figure 7-23: Dead Nest and Dead Nest Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Figure 8-1: Terminal Block and Input Connector on Network Card . . . . . . . . . . . . . . . . . . . . . . 8-6 Figure 8-2: Slave Boards Powered Through Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Figure 8-3: Slave Boards Powered Through RS-232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Figure 8-4: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Figure 8-5: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Figure 8-6: Master Network Card with Interface Card on Top . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Figure 8-7: Slave Network Card Powered Through Terminal Block . . . . . . . . . . . . . . . . . . . . . 8-11 Figure 8-8: Slave Network Card Powered Through RS-232 Cable . . . . . . . . . . . . . . . . . . . . . . Figure 8-9: New Motor Assembly to Be Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-10: Screwing Motor Drive Board in Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-11: Adding Grommet and Long Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-12: Sliding Network Card into Cover; Adding Long Spacers . . . . . . . . . . . . . . . . . . . 8-11 8-12 8-13 8-13 8-14
Figure 8-13: Sliding Both Covers Together; Adding Rainbow Cable . . . . . . . . . . . . . . . . . . . . 8-14
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Figures-5
Figure 8-14: Initialize Motors Menu Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-15: Initialize Motors Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-16: Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-17: Serial Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-18: SMC Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-19: Small Black Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-20: Metal Casing Unscrewed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-21: Clear Glass Casing Snapped Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-22: Large Black Inner Screw Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-23: SMC Air Regulator Turned Off (Left), On (Right) . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-24: Auxiliary Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-25: Air Valves with Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-26: K15 Vacuum Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-27: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom) . . . .
8-15 8-16 8-17 8-17 8-19 8-19 8-20 8-20 8-21 8-22 8-23 8-24 8-25 8-26
Figure 8-28: Extra Holes in K15 Interface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 Figure 8-29: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Figure 8-30: Dirty Filter (Left) Versus Clean Filter (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28 Figure 8-31: Blow-Off Adjustment Screw at PS Port When Using In-House Air . . . . . . . . . . . 8-30 Figure 8-32: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump. . . . . . . . . . 8-31 Figure 8-33: Various Styles of Vacuum Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-34: Vacuum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-35: Vacuum Assembly with Four Screws Highlighted. . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-36: Vacuum Assembly with One Solenoid Valve Removed . . . . . . . . . . . . . . . . . . . . Figure 8-37: Vacuum Assembly with Both Solenoid Valves Removed . . . . . . . . . . . . . . . . . . . Figure 8-38: Removing Gasket from Vacuum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-39: Vacuum Assembly with Gasket Still Attached. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-40: Vacuum Assembly with Both Solenoid Valves and Gasket Removed . . . . . . . . . Figure 8-41: Vacuum Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-42: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole . . . . . . . . . . Figure 8-43: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole . . . . . . . . . Figure 8-44: Vacuum and Blow-Off Override Buttons on Vacuum Generator . . . . . . . . . . . . . Figure 8-45: P1 Baseline Value Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-46: P1 Set at Least 8-10 Points Higher Than Baseline . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-47: P2 Set to 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-48: Error Code Set to Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-49: Green Indicator Light with High Number Showing Device Attached . . . . . . . . . . Figure 8-50: Computer Sliding Out of Cabinet on Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-51: Four Computer Base Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 8-32 8-32 8-33 8-33 8-34 8-34 8-35 8-36 8-37 8-38 8-39 8-40 8-40 8-41 8-42 8-43 8-45 8-45
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Figure 8-52: Sliding Computer Out of Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 Figure 8-53: Front Bolts Securing Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-54: Top Bolts Securing Lid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-55: Omron Sensor Controller Set to L-ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-56: Green and Red Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-57: Conditions of Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-58: LAN Setup Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-59: Local Area Connection Status Dialog BoxGeneral Tab. . . . . . . . . . . . . . . . . . . Figure 8-60: Local Area Connection Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . . . Figure 8-61: Internet Protocol (TCP/IP) Properties Dialog BoxGeneral Tab . . . . . . . . . . . . . Figure 8-62: Local Area Connection Properties Dialog BoxAdvanced Tab. . . . . . . . . . . . . . Figure 8-63: Windows Firewall Dialog BoxExceptions Tab . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-64: Selecting Run Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-65: Opening a DOS Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-66: PING Command with Replies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-67: IPCONFIG Command with Reply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-68: E-mail Invitation to WebEx Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-69: WebEx Meeting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-70: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-71: Backup Directory with Job Files, Old Program File, and New Zipped File. . . . . . Figure 8-72: Exatron Directory with Job Files and New Program File. . . . . . . . . . . . . . . . . . . . 8-46 8-47 8-48 8-48 8-49 8-51 8-52 8-53 8-54 8-55 8-56 8-57 8-57 8-58 8-58 8-59 8-60 8-61 8-62 8-62
Figure 8-73: Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63 Figure 9-1: Relays12-Volt (Left); 24-Volt (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Figure 9-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Figure 9-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Figure 9-4: Dimensions Listed From Smallest to Largest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Figure 10-1: PET-V84-B Figure 10-2: 700-421-1-C Figure 10-3: 700-421-2-C Figure 10-4: 700-421-3-C Figure 10-5: 700-421-4-C ...................................................... ...................................................... ...................................................... ...................................................... ...................................................... 10-2 10-3 10-4 10-5 10-6
Figure 10-6: 700-421-5-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Figure 10-7: 700-421-6-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Figure 10-8: 700-466-1-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Figure 10-9: 700-466-2-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Figure 10-10: 700-466-3-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
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Figure 10-11: 700-466-4-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-12: 700-466-5-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-13: 700-466-6-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-14: 700-466-7-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-15: 700-466-8-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-16: PET-C06-2-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-17: PET-C06-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-18: PET-H07-A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-19: PET-H59-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-20: PET-J37-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-21: PET-P14-10-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-22: PET-P14-1-V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-23: PET-P14-2-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-24: PET-P14-3-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-25: PET-P14-4-P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-26: PET-P14-5-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-27: PET-P14-6-A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-28: PET-P14-7-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-29: PET-P14-8-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-30: TAPE-875-5-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31
Figure 10-31: TAPE-875-8-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Figure A-1: Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Figure A-2: 24-Pin D Connector on Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Figure A-3: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A-4: Eight-Bit LED Checker #3000-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Figure A-5: TTL 24-Pin Connector with Pin Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-6: Typical RS-232 Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Figure A-7: Getting to HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 Figure A-8: Opening the HyperTerminal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26 Figure A-9: Naming a New Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26 Figure A-10: Selecting the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-11: Selecting the Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-12: Getting to Connection Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-13: Getting to ASCII Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A-14: Displaying Typed Commands Onscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 A-27 A-28 A-28 A-29
Figure A-15: Using Call to Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Figure A-16: Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Figure B-1: CMOS Setup Opened to Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected . . B-3
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Figure B-3: Advanced BIOS Features Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Figure B-4: Selecting CD-ROM Drive as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-5: CD-ROM Drive Selected as Boot Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-6: Saving Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-7: Acronis Program Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-8: Acronis Main Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 B-5 B-6 B-6 B-7
Figure B-9: Manage Acronis Secure Zone Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 Figure B-10: Manage Acronis Secure Zone WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . B-8 Figure B-11: Creating Secure Zone in Unallocated and Free Space . . . . . . . . . . . . . . . . . . . . . . B-9 Figure B-12: Specifying Size of Secure Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 Figure B-13: Activating Acronis Startup Recovery Manager . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager. . . . Figure B-15: Confirming Settings Before Creating Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-16: Secure Zone Successfully Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-17: Reviewing Properties of the Created Secure Zone . . . . . . . . . . . . . . . . . . . . . . . Figure B-18: Backup Disk Shipped with Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-19: Selecting the Backup Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-20: Create Backup WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-21: Selecting Entire Disk or Partition Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-22: Alternate SelectionIndividual Files and Folders Backup. . . . . . . . . . . . . . . . . Figure B-23: Selecting Partitions to Back Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-24: Explanation of Differences Between Full and Incremental Backups . . . . . . . . . Figure B-25: Restoration Based On Incremental Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-26: Restoration Based On Differential Backups . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-27: Selecting Backup Storage Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-28: Selecting a Full Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-29: Selecting an Incremental Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-30: Selecting a Differential Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-31: Selecting Backup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-32: Archive SplittingAutomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-33: Archive SplittingFixed Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-34: Drop-Down List of Fixed Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-35: Adding Optional Archive Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-36: Confirming Settings Before Creating Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-37: Progress Bar Displayed While Backup Is Created. . . . . . . . . . . . . . . . . . . . . . . . Figure B-38: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 B-12 B-13 B-14 B-15 B-16 B-16 B-17 B-17 B-18 B-19 B-19 B-19 B-20 B-21 B-21 B-22 B-22 B-23 B-24 B-24 B-25 B-26 B-27 B-27
Figure B-39: Archive Files Created. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27 Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right) . . . B-28
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Figure B-41: Acronis Main Screen with Restore Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-29 Figure B-42: Error Messages Due to Inserting Wrong Backup Disk . . . . . . . . . . . . . . . . . . . . B-30 Figure B-43: Restore Image WizardWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-30 Figure B-44: Selecting Archive File for Restoration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-45: Option to Verify Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-46: Selecting Partition or Disk to Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-47: Option to Resize Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-48: Resizing Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-49: Deleting Partitions on Destination HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-50: Option to Restore Additional Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-51: Confirming Settings Before Restoring Partition . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-52: Prompts to Insert Series of Recovery Disks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-53: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-54: Selecting the Recovery Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-55: Restore Data WizardWelcome. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-56: Selecting Location of Archive File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-57: Selecting Original or New Location for Restoration . . . . . . . . . . . . . . . . . . . . . . Figure B-58: Selecting Restoration Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-59: Selecting Archive Files to Be Restored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-60: Selecting Restoration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-61: Selecting Restoration Options Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-62: Selecting Whether to Overwrite Existing Files . . . . . . . . . . . . . . . . . . . . . . . . . . Figure B-63: Confirming Settings Before Restoring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-31 B-32 B-33 B-34 B-35 B-36 B-37 B-38 B-39 B-39 B-40 B-41 B-42 B-43 B-44 B-45 B-46 B-47 B-48 B-49
Figure B-64: Progress Bar Displayed While Data Is Restored . . . . . . . . . . . . . . . . . . . . . . . . . B-50 Figure B-65: Successful Completion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-50 Figure B-66: Restored Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-50
Figures-10
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Chapter 1: Safety, Support and Options

Chapter Overview
This chapter discusses the following main topics: Topic Exatron Safety Warnings Lock-Out Procedures Facilities Requirements Standard Warranty Exatron Support Services Warranty and Support Contracts End-of-Life Handler Disposal Significance of This Manuals Version Number Typographical Conventions Used in This Manual Terms Used in This Manual Page 1-1 1-3 1-4 1-6 1-8 1-8 1-21 1-21 1-22 1-22
Please read and understand this entire User Manual before installing or using your Exatron handler. A short glossary of terms used in this manual and other keys to understanding is found at the end of this chapter.
Exatron Safety Warnings

Typically, the handler is simply one part of a complete test system. It is the responsibility of the company purchasing the handler to properly train all handler operators in all of the safety practices required for every component of the test system. The following safety procedures must be followed at all times.
WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury. WARNING! Always reset all motors before running the machine. Do not run it without homing the motors.
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WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) button or click Pause on the screen.
Figure 1-1: EMO (Emergency Stop) Button
WARNING! If your Exatron handler is equipped with safety covers, never operate the handler without them. Never remove the safety covers. Never defeat any electrical interlock switch supplied with the handler. To avoid operator contact with moving parts, the Model 7000-BPR is equipped with fixed and moving covers. The fixed covers are screwed in place and should never be removed except for maintenance and then only by qualified maintenance technicians. The movable covers are supplied with interlocks. Exatron specifically disclaims responsibility and/or liability for any injury which occurs as a result of any interlock being defeated and/or bypassed, or for any injury which occurs as a result of any fixed cover being removed during operation. Using compressed air can be hazardous. It is the responsibility of the company purchasing the handler to properly train all handler operators in every aspect of the safety practices associated with the use of compressed air. WARNING! Never operate any Exatron system which requires compressed air without an approved air regulator and shutoff valve, such as that originally supplied with your system. WARNING! Never unplug a pressurized air hose while the air regulator is turned on. If your handler is equipped with a laser, follow all the federal and state safety regulations for safely operating the laser. Follow the safety warnings in the laser manufacturers manual. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser, if the handler is equipped with a laser.
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Lock-Out Procedures
Lock-Out Procedures
Lock-out/tag-out procedures should be followed when servicing or repairing the handler. This prevents an operator from turning on the handler when it may be partially disassembled and thus prevents damage or injury. Before servicing or repairing your handler, turn off the air regulator and lock it in the OFF position as shown in Figure 1-2. Then, if you have to leave the handler in an inoperable or unsafe condition, no one can turn it on by mistake. NOTE: Locking devices such as padlocks are provided by you, the customer. WARNING! Turn off the air regulator and lock it in the OFF position before servicing.
Figure 1-2: Air RegulatorIn ON Position (Left), in OFF Position (Center), in OFF Position with Lock (Right)
The handler has a lockable disconnect switch (Figure 1-3) that shuts off all AC power to the handler and computer(s). When using lockout procedures, turn off and lock this switch also.
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Figure 1-3: Lockable Disconnect SwitchIn ON Position (Left), in OFF Position with Lock (Right)
Facilities Requirements
Air Conditioning and Environmental Requirements
The Model 7000-BPR handler should be installed in a temperature-controlled, dust-free environment to preclude dust and dirt particles from contaminating its moving parts, especially those parts which come into contact with the devices being tested. The life of your handler is greatly enhanced by keeping it as clean as possible. See Chapter 8 for instructions. There are no special ventilation requirements.
Electrical Requirements
The power supplies for handlers shipped either within the United States or offshore have builtin switching electrical supply capability for 100-volt AC to 240-volt AC, 50 Hz to 60 Hz, at usually 5-10 amps. For more information see "Power Supplies" on page 2-10. However, the handler is wired for either 100-120-volt AC, 50/60 Hz, at 3 amps; or 220-240-volt AC, 50/60 Hz, at 2 amps. You must specify your choice when you order the handler. Your Model 7000BPR handler is wired for 100-120-volt AC, 50/60 Hz, at 3 amps. Tapers, if included, can be wired for either 100-120-volt AC, 60 Hz; or 220-240-volt AC, 50 Hz. You must specify your choice when you order the handler. If the handler is to be used in an electrically noisy environment or near large electromechanical equipment, Exatron recommends the use of a reliable power conditioner to filter line noise, surges, and spikes which can cause the handler to operate improperly or become damaged. CAUTION: Connect the power cord to earth-grounded power outlets only.
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Facilities Requirements
Vacuum/Pneumatic Requirements
Service calls made to the customer facility to correct problems caused by improper electrical supply are not covered by the Exatron warranty.
Vacuum/Pneumatic Requirements
The Model 7000-BPR system requires a supply of pressurized air at a minimum of 80 PSI at 2 to 5 CFM (depending on the number of vacuum generators), filtered for proper operation. The air supply must be clean (containing no particulate matter greater than 5 microns in size), oilfree, and dry (having a dew point of 36 degrees F to 38 degrees F) to operate correctly. Dirty, oily or wet air will cause the vacuum generator to malfunction and will make your system unreliable. If the handler is equipped with a taper, add 0.5 CFM of shop air to the CFM required for the handler itself. The external air source should be attached to the air regulator mounted on the handler base. Before turning on the air regulator and using the handler, make certain the compressed air line is attached to the air regulator fitting. Check to make sure the air regulator gauge on the external regulator measures the air pressure at 80 PSI, and adjust if necessary. To maintain these levels of pressurized air quality, replace the air filter (Exatron part #GPA-97075) in the air regulator of your handler after every 6000 hours or 12 months of operation, whichever comes first; or if your air regulator registers a pressure drop of 15 PSI. Moisture of any kind will travel through external and internal air lines. This moisture will coat these air lines and the insides of the handler's cylinders, causing them to stick or to stop functioning altogether. The best defense against this kind of contaminate is to prevent it from occurring in the first place by maintaining the clean air supply described above. If the air lines are allowed to become discolored or the moisture traps become overfilled, damage to the system will occur. The only corrective action to take at that point is to replace all of the air lines and to completely clean all of the solenoids supplied by those air lines. Handler damage due to improper air supply is not covered by the Exatron warranty.
Internet Access
It is strongly recommended that your handler be equipped with Internet access. This is to facilitate remote troubleshooting by Exatron engineers as necessary, and to save you larger onsite costs, the details of which are itemized in the "Customer Service Support Guide" on page 1-15. See Chapter 8 and especially "Remote Handler Control with WebEx" on page 8-59 for how we can help you troubleshoot remotely. Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We encourage our customers to put our systems on their networks and provide remote access to the system through the Internet. Exatron reserves the right to bill the customer for any on-site warranty work that otherwise could have been accomplished remotely.
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Uncrating the Handler

The Model 7000-BPR series handler will usually come in a wooden crate that will require some disassembly to remove the handler. Please inspect the system when it is removed from the crate for any obvious damage which may be the result of shipping. Contact Exatron and the shipping company immediately if you see any damage.
Mounting the Handler

For seismic safety, once the handler is installed in its designated location, do not leave it on unlocked wheels. Lock its wheels, then extend the leveling feet. See "Leveling Feet" on page 3-1 for instructions. Additionally, if local regulations require it, an optional tie-down kit is available from Exatron. This will permanently attach the handler to the floor so it cannot be moved. See Figure 10-1 on page 10-2. Call for a quote.
Standard Warranty
All Exatron products are under warranty for one year from the date of purchase. Exatron agrees to repair any mechanical or electrical assembly, subassembly, or entire unit that fails during normal use within its first year. The customer agrees to follow the recommended maintenance procedure as defined in this User Manual. Exatron does not warrant test contactors. Handler test contactors are fragile and may be easily ruined by operator abuse. Exatron uses the finest materials available in our contactor designs. Exatron does not warrant the following: Damage caused by improper packaging of equipment returned to Exatron for repair Damage caused by the shipping company Damage caused by natural catastrophes: flood, fire, earthquake, etc. Damage caused by equipment connected to improper power line voltages Damage caused by equipment connected to improper air supply: contaminated with oil, water, dirt, etc. Damage caused by operator abuse or improper practices cautioned against in this manual Damage caused by interface hardware not manufactured by Exatron Damage or malfunction caused by customer modifications Test contactors
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Standard Warranty
Customer In-House Service
Customer In-House Service

Except in the case of laser marking systems, Exatron encourages customer in-house equipment service and tries to make in-house service as easy as possible to perform. There are no "Void Warranty" warning stickers on Exatron handlers. By using the built-in diagnostic software and diagnostic tools, it is usually possible for the operator to isolate a problem quickly and effect a repair. The customer is responsible for all cost of in-bound shipping expenses. Standard out-bound shipping expenses will be paid by Exatron. In such cases where the customer requests specific out-bound shipping methods to be used, the customer is responsible for all shipping costs and any additional related charges.
Offshore Warranty Service

An Exatron handler purchased in the United States and then shipped offshore will be warranted through Exatron in California. Replacement parts are furnished for a period of one year from date of purchase with the exception of replacement contactors. In most cases, it will not be necessary to return the worn part from the offshore user location. To receive offshore service support, the handler must be purchased through your local Exatron representative, or an extended warranty agreement must be purchased directly from your local Exatron representative. Please supply the following information when requesting offshore service or replacement parts: The part number(s) required. If the part number is not known, photocopy or take a photo of the part and fax it to Exatron. The model number of the handler The type of device being run by the handler, such as: DIP, SOIC, SOJ, PLCC, LCC, SIP, PGA, PCB, ZIP, etc. The handlers serial number The full shipping address Any special shipping or customs instructions Method of shipment, such as: Federal Express, UPS, DHL, U.S. Mail, or the name of your chosen shipping company In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron.
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Exatron Support Services

For factory technical support, you can contact us in several ways. Call 1-800-EXA-TRON or 1-408-629-7600, between 8:00 A.M. and 5:00 P.M. Pacific time, Monday through Friday. E-mail us anytime at service@exatron.com. Fax us at 1-408-629-2832. When contacting us, please have your Exatron equipment close at hand, along with the following information: The model number of your handler with all its options (taper, tubes, etc.) The exact wording of any messages that appeared on your handler display. A description of what happened and what you were doing when the problem occurred. A description of how you tried to solve the problem.
Warranty and Support Contracts

The following three sample contracts show details of what is covered. They may be changed without notice.
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Service Contract
Service Contract
2842 Aiello Drive, San Jose, CA 95111
www.exatron.com 408-629-7600
SERVICE CONTRACT Rev H

for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract.. This Service Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. 1 year factory labor Installation of any update and diagnostic software as might be available Best effort response time, 1 to 3 business days typical Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this Service Contract: All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God
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Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract
Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Service Contract Schedule Exatron will make every effort to have a service engineer at the customers facility with in 1 to 3 business days of the call for service. There are no service response time guaranties. We do offer a 1 business day turn around service on a per occurrence basis. Please contact Exatron for details and quotation. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines which are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price Call for a quotation. There is a substantial cost increase for customers who do not have and/or allow our service engineer to connect the Exatron Product to the internet allowing for remote diagnostics. Spare Parts 25% discount on all Exatron spare parts, except consumables, during the life of the contract. Spare parts for OEM subsystems should be purchased directly from the OEM vendor. If purchased through Exatron, there is an additional markup and no discounts are available. Terms Call for a quotation.
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Service Contract
All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer are waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment. Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California. IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _David Ledezma______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
Handler Model Exatron PC
Original Customer PO# :__________________ Original Ship date#:______________________
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Preventive Maintenance Contract
2842 Aiello Drive, San Jose, CA 95111
www.exatron.com 408-629-7600
PREVENTIVE MAINTENANCE CONTRACT Rev J

for Customer TBD Street Address City, State, Zip
Please see our Customer Service Support document for detailed warranty details This contract shall commence on Starting Date for a period of twelve (12) months and shall be renewed only upon receipt of new purchase order for a new 12 month period. Exatron shall provide service by way of prompt, reliable technical consultation and service coordination with respect to Customers Exatron built products located at their TBD facility, full address. Please see section Product Movements, below, for more information regarding the location of the Exatron products covered by this contract. This "Preventive Maintenance Contract" includes: Perform Preventive Maintenance procedures as defined in the Exatron Manual. Clean, align and inspect handler for worn and/or damaged parts. Examine handler for signs of wear and notify the Customer. A list of required replacement parts will be supplied to the customer during each visit. Purchased parts may be installed during the next visit. Installation of any update and diagnostic software as might be available Scheduled PM visits only, as listed below. Typical same day shipment of spare parts Toll free 800-EXA-TRON support service phone line What is NOT covered by this "Preventive Maintenance Contract": All actual travel costs, see below The cost of all spare parts The cost of consumables and test contacts Un-scheduled service calls Any OEM equipment warranty/service costs (non-Exatron products) Operator and/or service training of customer personnel Shipping damage of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Ongoing camera & laser application support Any other Exatron products not specifically listed on this contract Service performed on Exatron-built products only: Service is strictly limited to the Exatron portions of a given system Service work on any OEM subsystem is to be purchased directly from the OEM This includes, and not limited to, bowl feeders, chillers, camera/vision systems, customer supplied equipment, label printers, laser markers, smoke extractors, and any large OEM subsystem used in the overall Exatron system
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Preventive Maintenance Contract
Please note: All laser markers require professional service. Improper service will void the OEM warranty and could result in personal injury and/or serious damage to the laser.
This contract does NOT extend the Exatron product warranty. This contract does NOT provide for any additional service work beyond the limits of this contract.
Preventive Maintenance Visit Schedule There will be two (2) preventive maintenance visits each year. The timing of each visit shall be mutually agreed upon by Exatron and the customer to prevent unnecessary disruption of Customer's plant operation. The dates of the mutually agreed semi-annual visits must be determined at least 30 days prior to its occurrence. One engineer will be dispatched to carry out the preventive maintenance work. PM Product Movements Preventive maintenance contracts are priced to specific locations. With the exception of movements between buildings on the same campus, any movement of the Exatron product covered by this contract during the period of this contract may result in a change in the price of the preventive maintenance contract, and the contract must be requoted. The value of any unused portion of this contract will be applied towards the new contract price. Exatron reserves the right to refuse service for machines that are moved to parts of the world considered unstable or dangerous. Service Operating Hours Preventive Maintenance service work shall be performed 8:00 AM to 5:00 PM, local time, Monday through Friday, excluding weekends and local public holidays. Availability of Products Any spare parts at site shall be made freely available by Customer to Exatron's engineer to enable remedial work to be carried out. In the event spare parts must be obtained from the factory in San Jose, California, the engineer may return to the customer facility to complete the work. Return to the customer facility will be determined by mutual agreement between Exatron and the customer. Price The PM contract is priced by the day. We recommend a minimum of 2 PM visits per year. We recommend a maximum of 4 PM visits per year. Prices DO NOT include any travel costs and/or spare parts if applicable. 2 PM visits per year at $1200 per visit ($2400 Contract Cost) 3 PM visits per year at $1100 per visit ($3300 Contract Cost) 4 PM visits per year at $1000 per visit ($4000 Contract Cost) Spare Parts Spare parts for OEM subsystems could be purchased directly from the OEM vendor and/or Exatron. Exatron manufactured spare parts to be purchased through Exatron only. Terms Call for a quotation. All actual travel expenses are NOT included and will be billed at the time: These include as a minimum the following expenses: Air fare as required Rental car and/or cab fees Lodging Per-diem food allowance Equipment and/or spare parts express shipping costs Travel expenses to the customer waived if within 50 miles of Exatron, San Jose, California. Site Medical Facilities Site medical facilities will be made freely available to Exatron's engineer(s) as needed for emergency medical treatment.
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Limitation of Liability During the initial warranty period of a system covered by this contract, Exatrons entire liability and customer's exclusive remedy will be repair or replacement of an assembly not meeting Exatron's standard warranty. Following the warranty period, Customer is responsible for any and all costs associated with repairs, replacement parts, etc. In no event will Exatron be liable to the customer for any damages including lost profits, cost saving, or other incidental or consequential damages arising out of the use or inability to use Exatron products referred to herein even if Exatron has been advised of the possibility of such damages, or of any claim by any other party. Customer will indemnify Exatron against any damage to Customers property and against any claims for loss or injury to any person or to the property of any person by reason of the Customers negligence or of any act or omission on the part of the Customers employees, subcontractors, assignees or agents arising out of this contract. Excuse of Performance Neither party shall be liable to the other party for any delay due to causes beyond its reasonable control, including but not limited to faulty instructions, lack of instructions, travel or shipping delays due to weather or other factors outside their control, shipper's error, acts of God, or strikes or other labor disputes. Law The validity, interpretation, and performance of this agreement, and any dispute connected therewith will be governed and construed in accordance with the laws of the State of California.
IN WITNESS WHEREOF, the parties have executed this Agreement by their duly authorized representatives as of the date and year stated at the top of this document. Customer TBD EXATRON
_____________________________________________________________________ By ___________________________By _Quang Truong______________ Title __________________________Title _Customer Service Manager____ Customer contact person(s) Phone number(s) Email(s) EXATRON PRODUCTS COVERED UNDER THIS P.M. CONTRACT Serial # Serial #
Handler Model Exatron PC
Original Customer PO# :__________________ Original Ship date#:______________________ PM Contract PO# :__________________ Exatron Invoice# :__________________ NOTE: LASER & LASER PC SERVICE/MAINTENANCE ARE NOT INCLUDED DATES FOR PREVENTIVE MAINTENANCE The Preventive Maintenance procedures will be performed two (2) times semi-annually as scheduled below: (Please fill out and return with signed copy of the contract.) 1: TBD 2007 PM Contract Quote#:______________________
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Customer Service Support Guide
2842 Aiello D rive, San Jo se, C A 95111
w w w .exatron.com 408-629-7600
C ustom er S ervice & S upport Rev K

Manager Factory service hours Phone numbers Fax number E-mail Quang Truong (or Eric Hagquist) 8:00AM-5:00PM M-F Pacific Time 408-629-7600 or 1-800-EXATRON 408-629-2832 info@exatron.com or qtruong@exatron.com
Standard Exatron Warranty: 1 year all Exatron parts other than test contacts and consumables 1 year factory labor. Warranty does not cover travel expenses for on-site service. See note, below, regarding Ethernet access for support All parts listed by OEM and in-house part numbers Typical same day shipment of spare parts PC Anywhere remote update and diagnostic software standard Self-service encouraged with on-line documentation and extensive built-in diagnostics Service contracts available See below Toll free 800-EXA-TRON support service phone line Major OEM subassemblies such as bowl feeders, lasers, vision systems, etc., have pass-through OEM warranties ONLY. No additional Exatron warranty Assume OEM warranties do not include on-site labor usually factory only Any unexpected OEM warranty/service costs passed on to customer at Exatron cost What is NOT covered by the Standard Exatron Warranty: On-site operator or in-house service training after install Consumables and test contacts Shipping damage of any kind Improper or lack of preventative maintenance Operator abuse of any kind Acts of God Acts of war Power line problems and damage Air supply problems and damage Any problems with OEM equipment not covered by OEMs warranty Ongoing camera & laser application support (see below) Ongoing Exatron updates added after shipmen Problems with non-Exatron supplied system components Please note: All of our products are quoted with factory installation. If this option is not ordered, then problems that arise from "self installation" are not considered covered by our standard warranty Exatron comprehensive manuals: Over the years our documentation has improved greatly. We now offer full color comprehensive manuals. These manuals are installed on the handlers hard disk and can be downloaded from our website, anytime. All manuals have fullcolor photos to help get the point across. To keep our costs down, our manuals have grown to cover all possible options and are now considered comprehensive. We then add customized chapters to the comprehensive manual with productspecific electrical schematics, master assembly drawings, and a detailed parts list.
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Self diagnostic support: All Exatron products have substantial built-in self diagnostic software. These diagnostics are well documented in our manuals. Typically every sensor, switch, solenoid, valve, lamp, motor, vacuum can be individually turned on/off and tested quickly. This is a great help with troubleshooting problems. Combine this with remote Internet access and just about all problems can be found quickly and at low cost to everyone. Void warranty stickers: There are no "void warranty" stickers on Exatron products, but there are some on some of our OEM add-ons. We do require that a properly trained service technician perform any service work on Exatron products. Laser self service: Exatron does NOT recommend customer self service for any of our laser products. There are substantial safety issues with lasers and they must be serviced by the OEM laser vendor. In some cases, Exatron can provide basic service work. Laser service work must be quoted on a specific as-needed basis. Any damage, of any kind, to the laser caused by improper service or operator abuse voids any remaining warranty. Factory customer operator and service training: Exatron will train the customers operators and/or service personnel if: The training takes place at Exatron The customer pays all of their own travel / lodging costs Exatron is given at least 30 day notice Exatron will then train on the next best thing we have in-house at that time (best effort) Exatron uses only standard Exatron manuals for training aids Any spare manuals must be purchased by the customer In most cases, we are willing to provide up to two days of training for up to 3 people at no cost during the buy-off of the equipment. Additional factory customer operator service training can be purchased for $600 per day for one person, $200 per additional person all trained at the same time. Typically we would limit our class sizes to 4 people maximum. The number of days required to train depends on the Exatron product(s) and the skill level of the people being trained. On-site training classes: On occasion, Exatron provides our customers with on-site training classes. This can be as simple as a few hours reviewing our standard documentation. Or a more formal class may be required. Exatron will quote on-site training classes based on the customers needs. Spare parts: Most spare parts orders are shipped the same day, if the order is placed before 1pm PST. We do all we can to maintain a good stock of commonly used spare parts. But there will be times were Exatron cannot supply a spare part overnight. The customer must maintain their own stock of spare parts based on their needs. All shipping costs will be charged to the customers account. Please specify shipping method at time of order. Exatron will hold all spare part orders if the customer has any overdue open invoices. Spare test contactors: It is expected that the customer will maintain at least a 60 day inventory of spare test contactors. In many cases, test contactors are custom designed. In many cases, we ship the test contactors as a lot. We do not maintain a stock of spares in these cases. Typical lead time is 3 to 4 weeks; longer is possible for unforeseen reasons. Spare part kits: Exatron offers a well stocked spare parts kit. Call for a quotation. Spare part long-term support: Exatron makes every effort to supply spare parts for the life of the equipment. We manufacture our own machine parts and our ability to find old drawings, for old parts, is excellent. As the handler ages, many of the non-Exatron made parts will no longer be available. In some cases, we may substitute used parts that still have some life in them. If all else fails, we can design in new parts or upgrade around the problem part; this can add substantial extra cost, but will also extend the working life of the handler.
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RoHS Lead Free Compliance: Exatron has been building equipment since 1974. We no longer use lead solder in any of our newly designed products. Some of our "newly built" older designs might in fact use older in-stock parts that are not RoHS compliant. We do have older stocks of spare parts that were originally made with lead solder. Some of these older parts will be used in newly built Exatron products that were originally designed years ago. This applies mostly to older PCBs, both bare boards and assemblies. This may also apply to older test contacts & cable assemblies. In the event the customer needs to have all spare parts, including older in-stock parts, the customer's original order must clearly indicate that RoHS compliance is required. Exatron reserves the right to re-quote as needed. There will be substantial price increases. With many of our older spare parts, we will need to generate new documentation, artworks, and buy a minimum number of parts to remanufacture just one spare part that is now RoHS complaint. All of these costs and a much longer lead time, will be passed on to the customer within the required re-quote. Product upgrades: As the product ages, there will be a time when Exatron will no longer be able to upgrade the product with new options that are constantly being added to our product line. We will do all we can to support the product to work as well as it did when it originally shipped. Spare computer parts: It is simply a fact that as computers get cheaper, they also become less reliable. Exatron does all we can to buy the highest quality and generic computer parts as possible. This is why we build our own PCs. Please note that computer parts typically DO NOT have long term support. In most cases, but not all, we can swap out one PC vendor with another. It is highly recommended that the customer buy a spare PC at time of order (included in some spare parts kits). We maintain a small stock of older computers, subject to prior sale. Recover disks: All Exatron PC based handlers are shipped with software recovery disks. We will store a copy as well at Exatron. This disk(s) will allow the customer to fully recover from a catastrophic computer failure. The disk will recover all of the installed software that was on the handlers hard disk at time of shipment. This disk will not always fully recover if the computer itself has to be changed out to a different type or upgraded version of MS Windows. It is up to the customer to maintain backup files for all job files and Exatron updates after the equipment is shipped from Exatron. Please do not make your only backup files on the Exatron computer. Software updates: Some customers ask for improvements that we add to all future versions. Sometimes we even find "bugs" and fix them. We are always making improvements. Exatron provides these generic software updates on request only. We strongly believe in the idea that "if it isnt broken, dont fix it" when it comes to software adding a change to fix one problem can often lead to more and worse other problems, so we specifically do not make software fixes unless really necessary. Should the customer request be considered by Exatron to be an enhancement, we reserve the right to quote as needed. Spare hard drive: Exatron highly recommends adding a spare hard drive to our computers. This can be ordered at time of order. Adding a disk drive after shipment will require an on-site service call and is not covered by our standard warranty. 8-to 5-phone support: Exatron offers toll free (800-EXA-TRON) phone support, 8am to 5pm Pacific Time, Monday Friday, at no extra cost for the life of the equipment. Most questions are answered on the spot. More complicated issues will take longer. At some point Exatron may require the customer to purchase an on-site service call or return the equipment to Exatron for repair. Internet support: Exatron strives to maintain low capital acquisition costs and low service costs for our customers. A key part of this strategy is the use of the Internet to provide software updates and perform remote service on our systems. Software support in the field can be extremely expensive to the end user, so high-speed connections are an excellent money-saving tool. We strongly encourage our customers to put our systems on their networks and give us access to the system over their networks.
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Internet access software is included with every Exatron PC-based handler. In most cases, handlers can be connected to Exatron over any Internet port as long as the customer initiates the connection. There will be substantially higher service and engineering costs to our customers who cannot provide Internet access to our products. OEM equipment: Many Exatron products are systems built with additional third party OEM products. These products include laser markers, chillers, smoke extraction, vision/camera systems, bowl feeders, label printers, and other big ticket non-Exatron products. In every case, Exatron will require the OEM to pass its standard warranty through to the end user. In every case, Exatron will do all we can to correct any system problems. The specific service policy for the non-Exatron product will be determined at time of order. Most of our OEM products do not include on-site support or return shipping costs without a specific additional order at time of the original system order. In the event an OEM product is supplied by the customer, Exatron will only guarantee the initial integration. This integration must be bought off at Exatron prior to shipment. Exatron will not offer any additional warranty from that point in time. Exatron service work on OEM equipment: Service work is typically limited to repair of Exatron products only. We will make every effort to service our OEM partners equipment to the best of our ability. Should the OEM product require service beyond our limited ability, any and all costs required to bring the OEM equipment back to working order will be passed on to the customer. ONGOING CAMERA AND LASER APPLICATION SUPPORT: Exatron systems that require machine vision (cameras) and/or laser markers include the initial application development only. Depending on how the system is used, ongoing application support may be required. We encourage customers to develop sufficient in-house familiarity with the vision and laser systems to accomplish this themselves. However, in the event that additional application support is needed, Exatron considers this not to be covered by warranty. Applications support is available from Exatron at a price to be determined on a case-by-case basis. Exatron customers are also encouraged to seek applications support directly from the camera and/or laser vendor(s). Third-party service: Exatron has working relationships with qualified third-party service providers in Asia and Europe. Please see our web site for contact information. The customer is free to directly contact any of these service providers. Each has their own pricing structures. Returned to the factory repair turn-around times: Exatrons in-house repairs are billed at $75 per hour, 1 hour minimum. All products sent in to Exatron for repair must have an RMA number. If there is no RMA number, turn-around times can be significantly longer. Work performed 8am-5pm Pacific Time normal business days only Standard service turn-around time (with RMA#) ...typically the next day, best effort Rebuilds & engineering turn-around times...to be determined as needed 1 business day response subject to availability at the time (see below) Field upgrades and service call turn-around times: On-site turn-around time: We will make our best effort to provide on-site service as quickly as possible. Our standard warranty does not cover travel expenses. We will waive our technicians time and spare part costs during the warranty period. This does NOT apply to adding newly purchased upgrades. There will be a substantial increase in travel costs for immediate/overnight travel. All of these costs are all passed on to the customer.
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Field upgrades lead times must be quoted and confirmed at time of order. All field upgrades are quoted, open ended. We will do all we can to make a field upgrade go as quickly as possible. All costs for any unforeseen delays, for any reason, that requires the Exatron technician to stay extra days or make a return visit will be passed on to the customer as required. One-business-day guaranteed response time: Subject to availability at the time (see below) In-warranty service costs: On-site service within the USA (no Internet access) In the event Exatron is required to provide an on-site service call, where the problem could have been corrected with Internet access prior to the service call, Exatron will bill all costs for the service call at Out of Warranty service rates. Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service within the USA (with Internet access) Labor performed at no charge within our Standard Exatron Warranty (see above) Labor and travel time will be billed for any work for what is NOT covered by the Standard Exatron Warranty (see above) All actual travel expenses billed to the customer On-site service outside the USA (no Internet access) All actual travel expenses billed to the customer and $1875.00 per day, full payment received prior to the service call On-site service outside the USA (with Internet access) All actual travel expenses billed to the customer and $1200.00 per day, full payment received prior to the service call Field upgrades and out-of-warranty service costs: On-site field upgrade or service within the USA (no Internet access) Labor performed at $200.00 per hour, day minimum All actual travel expenses billed to the customer On-site field upgrade or service within the USA (with Internet access) Labor performed at $150.00 per hour, day minimum All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer On-site field upgrade or service outside the USA (with Internet access) Labor performed at $1500.00 per day All actual travel expenses billed to the customer Remote software engineering costs (8am to 5pm Pacific time, Monday-Friday; excludes local holidays: On-site remote software engineering within the USA Labor performed at $150.00 per hour, one hour minimum After hours service, labor performed at $250.00 per hour, one hour minimum On-site remote software engineering outside the USA Labor performed at $200.00 per hour, one hour minimum After hours service, labor performed at $300.00 per hour, one hour minimum
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Blanket service purchase order for service/spares: Customers who would like the fastest service at the lowest cost should consider opening a blanket service purchase order. With a standing open P.O. Exatron can respond immediately to customers employees requests for service and/or spare parts. This saves the down time required for Exatron to quote and the customer to generate a PO. Exatron will bill as needed at the time. We recommend a minimum of $5,000.00 per year Contact Exatron for terms. PM contracts: Sold by the day, $1,000 per day, plus travel and living expenses. Please contact Exatron for a copy of our PM Contract. One-business-day turn-around on-site service trips: Available on normal USA business days only Subject to availability at the time, this is not a guarantee Quoted on a "per trip" basis We will bill at the premium rate if Exatron is required to have a service technician on-site within 1 business day. Any unforeseen, no fault of Exatron, travel delays will be still billed at the premium rate. Exatron best effort on making necessary repairs only Flat daily rate, no discount for repairs made in less than 8 hours Service price schedule: One-business-day on-site service trip within the USA (no Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip within the USA (with Internet access) Labor performed at $1,500 per day All actual travel expenses billed to the customer $1,000 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (no Internet access) Labor performed at $3,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* One-business-day on-site service trip outside the USA (with Internet access) Labor performed at $2,000 per day All actual travel expenses billed to the customer Travel time added to 1 Business day guarantee $1,500 premium for guaranteed 1 business day service response time* * Subject to availability at the time. One-business-day response time starts at time of departure from Exatron; travel time not included. There will be a substantial increase in travel costs for overnight travel. All of these costs are all passed on to the customer. Terms: Terms to be determined at time of service call. Field upgrade terms will be added to our quote. Actual travel expenses include: Air fare as required (All tickets to be purchased thru Exatron's travel agent) Rental car and/or cab fees Lodging Living expenses Field upgrade and all on-site service call shipping costs: In the event a spare part(s) needs to be shipped overnight to a customer's site during a service call or field upgrade. We will ship the package via the customer's account with the shipper. Should Exatron be required to ship via our account, we will then bill the customer for all shipping costs at actual cost plus 50%
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End-of-Life Handler Disposal
End-of-Life Handler Disposal

Exatron has no time limit on Exatron product support. We will make every effort to repair any of our products, no matter how old it is. Our never-ending support greatly extends the life of many of our products. Exatron offers trade-in value on any of our products as part of a new Exatron equipment purchase. Exact terms are subject to quote at that time. This applies to any used Exatron product as a trade-in on any new Exatron product. We will service our products even when the product is not purchased directly from Exatron. This makes the resale value of Exatron products high as compared to many of our competitors. The customer can sell the product to a third party, used equipment vendor, or online as, for example, on eBay. Exatron will always offer spare parts, service contacts, and rebuilds of any of our products. Most of the materials used in the construction of our products can be recycled. When it comes time to finally retire an Exatron product, the customer can ship the product back to Exatron, at the customers expense, and we will quote the cost to dismantle and recycle the handler. In many cases, there is no charge for this service other than any third-party disposal fees as required. Whenever possible, reusable components will be offered as a donation to local schools. Please note that in many cases, Exatron builds systems using major third-party pieces of equipment. These include lasers, printers, camera inspection, chillers, fume extractors, and other large OEM (original equipment manufacturer) subsystems. Exatron will attempt to provide the same support as best we can for these subsystems. Exact details cannot be determined until the day comes that end-of-life service is required. The customer is free to contact the OEM directly for its end-of life service policy and then deal directly with that OEM.
Significance of This Manuals Version Number

The version number on the cover page of this manual indicates two levels of revision. The first number is incremented for brand new manuals or complete overhauls, including addition or deletion of chapters. The second number is incremented for small section changes and additions. For example, version 2.0 would refer to a completely redone manual or one that has had chapters moved, added, or deleted. The jump from 2.0 to 2.1 might include new or updated procedures, new screens or photos, or updated sections.
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Typographical Conventions Used in This Manual

Names of input boxes and buttons are displayed in bold type, such as: Click the Start Test button. Messages displayed on the hardware or software are shown in bold monospaced type, such as: If the tester responds correctly with an "R," you see the message: Pass checking tester. Emphasized words and phrases are displayed in bold and italicized type, such as: Never lubricate the lead screws.
Terms Used in This Manual

Bin Refers to a physical output location, such as a tray, bucket, or tube. Contrast with sort. A positive air pressure in the vacuum lines, used to break any residual vacuum between the pickup head and a device it was suctioning. Blow-off
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Terms Used in This Manual
Context menu
A pop-up menu that is displayed when you right-click over an area or item. It offers actions appropriate to the item.
Figure 1-4: Context Menu
Device
A generic term that refers to the chip, package, or other part processed by the Exatron handler. A down-pointing arrow at the right end of an input box. Click the arrow to view and select from the possible options. Some drop-down boxes have a slider bar that you can slide up and down to view even more selections.
Drop-down arrow
Figure 1-5: Drop-Down Arrow
Group box
A collection of input boxes, buttons, etc., on a window that are grouped together by function and purpose. They are usually surrounded by a thin border and a box title.
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Figure 1-6: Group Box
Home position
The location that each motor returns to each time the handler is reset. A box where you can type in text or numbers.
Input box, or box
Figure 1-7: Input Boxes
Sort
Refers to a logical output location; a type of test result. Contrast with bin. The component of a vacuum generator that sucks air in one hole as air pressure is forced along the pathways, thus causing a vacuum. Vertical, up-and-down axis. The pickup nozzle lowers and rises on the Z axis.
Venturi
Z axis
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Chapter Overview
This chapter discusses concepts of how your handler works. Following chapters show you how to put these concepts into practice and carry out procedures. This chapter deals with the following main topics: Topic How the System Works Modes of Testing Mechanical Systems Electrical Systems Pneumatic Systems Tape-and-Reel Assembly CE Marking Standard Practice and Options Page 2-2 2-4 2-4 2-8 2-14 2-18 2-22
This chapter will familiarize you with the various parts of the system hardware, what they do, and how they work. Exatron recommends that you read this part of the manual in the presence of the system to facilitate reference to the actual system. The parts of the system are identified as shown in this chapter. The Exatron software is discussed primarily in Chapters 4 through 6.
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How the System Works

Various configurations of the Model 7000 may have a bowl feeder input, one or more test sites, top and/or bottom cameras, laser, up to 8 rotary sorting buckets, and/or taper output. A pickup wheel rotates pickup heads from the bowl feeder, around to the test site(s) and possibly a laser mark site, and then to the drop-off site to the output sort wheel. Devices that are not dropped to the output sort wheel are carried on around to a taper output.
Figure 2-1: Handlers Input Side with Bowl Feeder and Test Site
Figure 2-2: Handlers Output Side with Sort Wheel and Taper
The order of movement for Model 7000-BPR occurs in two phases: the rotation phase, and the pick/drop phase.
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How the System Works
1. Rotation phase: > Both the lower plate on the pickup wheel and the output sort wheel rotate at the same time. The lower plate on the pickup wheel rotates clockwise 1/4 turn. The output sort wheel rotates devices in any of 16 carriers around to 8 sort buckets. It moves 1/16 of a turn with each move, so that each of the 16 carriers can receive a device from the pickup head if appropriate. 2. Pick/drop phase: > When the pickup wheel stops, the 3 pushers on the top stationary plate of the pickup wheel push their pickup heads down. Simultaneously, the pickup (Z1, after homing) at the bowl feeder gets a device from the bowl feeders dead nest; the pickup at the test site puts a device into the test socket; the pickup at the output wheel drop-off drops a device into a carrier of the output sort wheel (if its device is destined for an output bucket); and the pickup at the taper puts a device into the tape pocket (if its device is destined for the taper output). > When the output sort wheel stops and each device reaches its intended sort bucket, the sort gate retracts and opens the floor of the carrier, letting the device fall into the correct sort bucket. 1 14 15 16 Z1 Pickup wheel Z3 1 2 3 Z2 4 5 6 8
Figure 2-3: Simplified Diagram of Major Features
Test site Z4
16 carriers
2 12 11
8 sort buckets 3
13
Bowl feeder
Output sort wheel
4 10 9 8 7 7 5
Tape and reel
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Modes of Testing
One mode of testing is Single-Value Mode, in which one type and size of device is put in the bowl feeder, tested, and directed to pass or fail sorts. All the resistors have a single resistance deviation tolerance. Fail sorts are directed to bucket 3, "Reject." Pass sorts may be directed to the taper (sort 1) or to bucket 7 with the "GOOD 1" label at sort 8. The other mode of testing is Multiple-Value Mode, in which one size of device is put in the bowl feeder, tested, and directed to various pass sorts, according to their electrical resistance. Most of the eight sort buckets are used in Multiple-Value Mode, where 5 different good electrical resistance measurements are sorted to the 5 "Good" buckets at sorts 4-8 in buckets 3-7.
Mechanical Systems
Motors
Model 7000-BPR is equipped with five motors. Three servo pusher motors are on the stationary plate on top of the pickup wheel, and they push the pickups down to the various sites. The other two motors are rotary motors. One drives the pickup wheel and the other drives the output sort wheel (Figure 2-5). Whereas the four pickups rotate on the pickup wheel to the four positions, only three are pushed down by the three stationary pusher motors. These stationary pusher motors are positioned over the bowl feeder dead nest pickup site, the test site, and the taper drop-off site. No pusher motor is over the drop-off to the output sort wheel; the pickup merely turns off the vacuum on the tip and lets the device drop.
Figure 2-4: Pusher Motor
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Mechanical Systems
Pickup Heads
Figure 2-5: Pickup Wheel Rotary Motor (Left); Sort Wheel Rotary Motor (Right)
Figure 2-6: Rotary Motor Drivers
Pickup Heads
Three of the pickup heads are pushed down to three sites: at the bowl feeder pickup, the tester, and the taper. The drop-off to the output sort wheel has no pusher, as it does not need to descend there.
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Figure 2-7: Pickup HeadsOver Test Site (Left), Over Taper (Right)
The pickup head assembly includes a servo motor driving a chain which turns a short lead screw, which in turn drives the pickup head shaft down.
Lead Screws
Each of the three pushers uses a small lead screw. The lead screws are PTFE-baked and employ a Delrin nut for long-term reliability. As each lead screw is used, the teflon gradually wears off the lead screw and embeds itself in the nut to smooth out any irregularities in the nut, thus enhancing long wear.
Figure 2-8: Lead Screw on Pusher
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Mechanical Systems
Sort Buckets
Sort Buckets
The eight output sort buckets are numbered for sorts 2 through 9. (Sort 1 goes to the taper.)
Bucket # 1 2 3 4 5 6 7 2 3 4 5 6 7 8
Sort #
Label OPEN REJECT GOOD 5 GOOD 4 GOOD 3 GOOD 2 GOOD 1
Mode both modes both modes Multiple-Value Multiple-Value Multiple-Value Multiple-Value Multiple-Value Single-Value
Use Open resister that is not connected Failed resistance value Sort for one of 5 passing resistance values Sort for one of 5 passing resistance values Sort for one of 5 passing resistance values Sort for one of 5 passing resistance values Sort for one of 5 passing resistance values Sort for the passing resistance value Residual devices left from a previous run
CLEAR
both modes
Features of the sort buckets include: Easy to remove Plexiglass front cover Holes for optional padlocking in place A Bucket Present sensor to detect whether each bucket is in place or not
Figure 2-9: Sort BucketsTop View (Left); Front View (Right)
One available option is to upgrade sort buckets to "smart" buckets. This includes the option in the software to clear devices-in-bucket counts or not when the bucket is removed. A 24-volt solenoid in back locks each "smart" bucket in place.
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Two sensors are associated with each "smart" bucket. The sensor in back sees the bucket (Bucket Present sensor). The fiberoptic sensor inside performs two functions: Counts devices as they fall in. Warns when bucket is full.
Anti-Vibration Feet
The handler is leveled by four feet, each of whose length can be individually set. A locking nut keeps each foot secure once it is at the correct height. The feet are equipped with shock-absorbing rubber pads to isolate the handler from external vibrations. Each foot can be individually leveled.
Figure 2-10: Anti-Vibration FootTop (Left), Bottom (Right)
Electrical Systems
Main Disconnect Switch
Your handler is equipped with a main disconnect switch (Figure 2-11). Turning off this switch shuts off AC power to the handler and its computer. Therefore, all computers connected to the handler should be shut down properly before turning off this switch. When the main disconnect switch is turned off, it can be locked so that repairs can be made to any component without danger of accidental startup. Thus, it can be used as a lockout procedure.
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Electrical Systems
Emergency Stop Button
Figure 2-11: Main Disconnect SwitchIn OFF Position with Lock (Left), In OFF Position (Center), in ON Position (Right)

The EMO (emergency stop) button can be pushed in anytime there is a need to disable the motors and shut off the 24-volt DC. However, it leaves the computer running, so that when Auto Run is continued, the operator is given the choice of restarting where the handler left off with the device count. It is released by being turned clockwise until it pops out again.
Figure 2-12: Control Panel Buttons
HALT and RUN Buttons

On handlers equipped with HALT and RUN buttons, these act to pause and restart Auto Run.
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After pushing in the HALT button, you must push it a second time to release it before you can effectively push the RUN button to restart.
Power Supplies
The Model 7000-BPR uses two power supplies, both "switching" type. The first supplies 24-volt DC for the servo motors and the solenoids. Input is 100 to 240-volt AC and 50-60 Hz. Output is always DC. It auto-selects the correct input voltage. The second power supply is an ATX-style supply for the PC-104 motherboard. The CPU ATXstyle power supply for the PC-104 allows for manual switching. It supplies multiple voltage whatever is required by standard ATX specifications. Input is 115 or 230-volt AC and 50 or 60 Hz, switchable.
Figure 2-13: 24-Volt DC Power Supply
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Electrical Systems
Power Supplies
Figure 2-14: CPU Power Supply Installed
Figure 2-15: ATX Power Supply Switched to 115 Volts (Left) and 230 Volts (Right) Input
The PC-104 motherboard uses all voltages of the ATX power supply. The PET-C06 I/O PCB uses 5 volts from the ATX power supply. If your handler stands on its own frame, the power supplies are in the CPU box. If your handler is a benchtop model, the power supplies are on the bottom of the machine.
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Fuses
The fuses for the handler are standard fuses.
Figure 2-16: Fuses
When the handler is plugged into a power source, the bottom AC fuse lights up. When the black power switch is turned on, the middle +5-volt DC fuse lights too. When the yellow CPU reset button is turned on, the top +24-volt DC fuse lights in addition to the other two.
PC Boards
PCB PCM-8152 PET-C06 8000-N41 COM041616 8000-D14 Comment This is the main computer board for the Model 7000-BPR handler. It uses a PC-104 bus, which allows connection to the PET-C06 board. This PC-104-based board is connected to the motherboard via the PC-104 bus. This board routes all the I/O signals for the motors, air solenoids, and sensors. The 8000-N41 USB board is designed to go with COM04-1616, which is a new I/O board. This USB to buffered digital I/O board has an individual serial number that must be recorded in the software before the board can be recognized and used. If the handler is equipped with a taper, an 8000-D14 board is added to the taper. The D14 board provides 24V and 5V to the taper solenoids and sensors.
Hub
If your handler has a large number of motors, it may have a serial or network hub or adapter to add serial COM ports.
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Electrical Systems
Carrier Solenoids on Output Sort Wheel
Figure 2-17: Serial Hub or Adapter
Carrier Solenoids on Output Sort Wheel

The output sort wheel has 16 carriers to rotate devices to their appropriate output buckets. Each carrier gate is opened by a solenoid pulling back the floor of the pocket, allowing a device to drop into the output bucket. A sensor at each carrier detects the open or closed state (Figure 2-19, Figure 2-20). The sensor light is on when the carrier is in its default closed state.
Figure 2-18: Output Sort Wheel with 16 Carriers and 8 Buckets
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Figure 2-19: Carrier Gate Closed
Figure 2-20: Carrier Gate Open
Sensors
Sensors confirm to the Exatron software that various moving parts are at the positions they should be. For more information, see "Input Group Box" on page 4-4.
Pneumatic Systems
Pickup Head Shaft
The pickup head shaft is bored through and the vacuum/blow-off pressure passes through the shaft to the suction cup pick-up. Suction cups are available in various sizes, including 2, 4, 6, 8, and 10 millimeters. The typical size is 6 mm. In general, the preferred size is that which
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Pneumatic Systems
Main and Auxiliary Air Regulators
covers the largest possible surface of the device without running off the edge of the part or interfering with any other features of the device. However, there may be situations where a smaller suction cup is preferred, specifically in the case of bare silicon devices (FBGA, BGA, etc.).
Main and Auxiliary Air Regulators

The main air regulator "steps down" the air pressure from the incoming supply for the entire handler. This air regulator is mounted on the rear right corner of the base. The regulator assembly includes two oil/water particulate traps which should be visually inspected on occasion (see "Checking the Moisture/Dirt Trap in the Air Regulator" on page 8-18). This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices from the trays. The incoming air line exits the regulator and splits to supply the needs of the entire system. Adjustment knobs
Figure 2-21: Auxiliary Air Regulator on Left; Main Air Regulator on Right
The auxiliary air regulator "steps down" the air pressure for use by the bowl feeder. It should be set to about 20 PSI.
Vacuum Generator with Sensor

The Model 7000-BPR is supplied with a vacuum generator unit for each pickup head, mounted under the pusher disk. When the vacuum is engaged, a hissing noise is heard from its exhaust. It is controlled by an electric valve which is controlled by the handler electronics. In addition to creating a vacuum, the vacuum generator also acts as a regular air valve. It can produce a small positive air pressure, or blow-off, in the vacuum lines. This positive air pressure is used to break any residual vacuum between the pickup head and a device it was suctioning.
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The vacuum sensor notes when a device is released from the pickup head. It sends a signal to the Exatron software to increment the count of devices placed in various sort categories.
Figure 2-22: Vacuum Generator for Each Pickup Head
A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow-off pressure. CAUTION: Be careful when adjusting this screw, as loosening it will have the effect of increasing the blow-off pressure, but if the screw is turned too much it will come out and render the blow-off inoperable. Refer to the vacuum generator manufacturers manual for a drawing of the location of the adjustment screw. The vacuum generator is fitted with an electronic sensor that measures the strength of the vacuum drawn through the air lines. The sensor measures in centimeters of mercury (cmHg) and displays the result on the small LCD screen of the sensor. When the vacuum is engaged, the display should give a reading for the level of vacuum in the system. The sensor puts out a signal when a given level of vacuum is reached, indicating the vacuum has a secure hold on the device being lifted. For instructions on calibrating the vacuum generator, see "Checking and Setting the Vacuum Generator" on page 8-36. Finally, note the small white filter on the vacuum generator. If this filter becomes visibly dirty or contaminated, it must be replaced. See "Vacuum Generator Air Filter" on page 9-2 for the part number. CAUTION: A dirty filter causes poor handler operation. Replace your filter!
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Pneumatic Systems
Bowl Feeder Air Valve Manifold
Figure 2-23: Dirty Filter (Left) Versus Clean Filter (Right)

Pressurized air for the air cylinders at the bowl feeder air jets is controlled by a series of 24volt DC air valves mounted on a manifold block. Each air hose is differentiated by color to better see which flow control goes to which air jet.
Figure 2-24: Air Valves on Manifold Block (Left); Colored Air Hoses to Bowl Feeder Air Jets (Right)
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Tape-and-Reel Assembly
Some handlers are equipped with a tape-and-reel assembly, or taper. Model 201 tapers have an adjustable-width tape track that can accommodate devices of various widths. Model 202 tapers have a fixed-width tape track that can accommodate devices of only one fixed width. Model 202 may also come with changeover kits for different sizes or types of devices. A handler equipped with either taper places passed devices into a carrier tape which is then sealed with a sealing tape by either pressure or heat. The supply reel containing the carrier tape is the lower one, sometimes made of cardboard. The takeup reel is directly above it, usually made of plastic. The supply reel containing the sealing tape is toward the front.
Supply reel with sealing tape Empty/ outof-pocket image sensor Output or takeup reel
Tape trackcounterclockwise direction
Taper alignment screws Supply reel with carrier tape
Figure 2-25: Reels on Taper
The carrier tape is fed in a counterclockwise direction, forward along the underside of the tape track, then backward along the top of the tape track. On the top surface, the gap sensor detects the hole in the center of the empty pocket, and signals the position to the pickup head. When the empty pocket intersects the path of the pickup head, the pickup head places a passed device into the tape pocket.
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Empty/out-of-pocket sensor
Gap sensor Pickup head nozzle

Figure 2-26: Tape Track with Sensors and Pickup Head
Behind the path of the pickup head, an image sensor ensures that a device is present and seated correctly in each tape pocket. Then the filled carrier tape is sealed, either with pressure-sensitive sealing tape or heatsealed cover tape. If a pressure head is used to seal, the pressure is continuous; but if a heat seal head is used to seal, the heat seal head is pressed against the tape only intermittently to prevent burning. Wheels under the PSA seal head blade facilitate the tapes movement and reduce pulling tension from the drive gear.
Figure 2-27: Pressure Roller Block, Seal Head, and Image Sensor
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When a specified number of pockets have been filled, the takeup reel motor is activated long enough to wind the slack tape onto the upper takeup reel. The drive gear drives the tape along, with teeth that protrude upward to fit the holes on the side of the carrier tape. The pinch roller on the pressure roller block presses down on the tape, keeping it meshed with the teeth of the drive gear (Figure 2-28).
Figure 2-28: Pressure Roller Block (Left); Pinch Roller on Pressure Roller Block (Right)
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Sensor lights
EMO (emergency stop) button
Heater controller displays Override button lights Heater fuse
Takeup arm
Track width locking knob
Track width adjustment knob

Figure 2-29: Other Features of Taper (Model 201)

The EMO (emergency stop) button on the taper plate shuts down everything on the taper only, including the heat seal; whereas the EMO button on the body of the handler stops all motors. Pressing the tapers EMO button causes a taper error message to be displayed on the Auto Run window. The operator then has the option of aborting the job run, or making any necessary adjustments and then selecting the option to continue the run.
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Override Buttons
The override buttons on the taper plate accomplish the same thing the software can do, but in a more direct way. Either may be used, according to the operators convenience.
Figure 2-30: Taper Override Buttons
Taper Buttons Button Top white Second blue Third yellow Bottom green Affects Seal head Customizable option Takeup reel motor Customizable option Action When pressed, seal head is lowered onto the tape n/a When pressed, takeup reel moves, tightening tape slack n/a
CE Marking Standard Practice and Options

Certain options may help your handler meet certain local or federal standards, such as the European CE Marking. The features shown below do not constitute a warranty that a handler equipped with them will meet any particular standards. We self-certify our products as CE Marking-compliant. Some handlers have been CE Marking certified by independent parties. If you need third-party CE Marking certification, you can order this as an extra option.
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CE Marking Standard Practice and Options
Override Buttons
All handlers built on their own frame are equipped with a main disconnect switch (Figure 231). Turning off this switch shuts off all AC power to the handler and computer.
Figure 2-32: Gold Alodine Finish on Interior Surfaces
Conductive gold alodine (Figure 2-32) is a microscopic thin film Exatron uses on aluminum sheeting to provide increased corrosion resistance and impose desired electrical resistance characteristics; that is, to help with EMI shielding.
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Figure 2-33: Ferrite EMI Noise Filter
An EMI filter is available as an extra option when CE Marking certification is desired. The EMI line filter smoothes out noise signals coming in on the power line.
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Chapter Overview
This chapter discusses the following main topics: Topic Setting Up Your New Handler Changeover Kits for Various Device Sizes Powering Up the System Shutting Down the System Setting Up a Taper Getting Acquainted with the Main Window Verifying the Factory-Installed Job File Copying the Job File for Modifications Opening a Job File Fine Tuning Overview Saving the Job File Changing the Password Page 3-1 3-3 3-4 3-5 3-7 3-26 3-27 3-28 3-29 3-31 3-31 3-31
Setting Up Your New Handler

Your new Model 7000-BPR handler comes complete and set up, including the software and the job file to get you started.
Leveling Feet
If you have a cabinet model, you must lock the wheels (casters) and extend the feet to make the handler level. This increases handler stability and helps prevent movement in case of earthquake. If desired, use brackets to anchor the feet to the floor after leveling. When you get the handler to the exact position you want it, lock the wheels down by pressing down on the lever of each wheel to prevent movement. Then you can engage the leveling feet.
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Figure 3-1: Wheel Unlocked (Left), Locked (Right)
Next, engage the anti-vibration leveling feet (Figure 3-2). Each anti-vibration foot is attached with a right-handed thread. Level the handler by screwing each foot down. Use a carpenters level for best results.
Figure 3-2: Anti-Vibration Foot
If you have a tester from another vendor, you will need to install it at the test site. Follow the instructions from the tester vendor.
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Changeover Kits for Various Device Sizes
Leveling Feet
If Exatron was supplied with sample trays and devices from your company while your handler was being built, the job file that is installed on your handlers computer is factory preset to work with your tray configuration. All you need to do is verify that all the parameters are to your liking. This prodecure is covered in "Verifying the Factory-Installed Job File" on page 3-27. NOTE: Exatron recommends that if you make changes to the job file, you save the changes with a new file name, so that the original job file is preserved with its initial parameters. Instructions on saving a job file are found in "Copying the Job File for Modifications" on page 3-28. If at a later time you change your tray configuration or some hardware, you may need to set up a new job file. Instructions for calibrating a new configuration are found under the section "Fine Tune Window" on page 4-19.
Changeover Kits for Various Device Sizes

Changing device sizes for processing may require changing some or all of the following parts. For instructions, see "Replacing the Tape Track" on page 3-9, "Changing Seal Head Blade" on page 3-19, "Removing Bowl Feeder Changeover Parts" on page 7-11, and "Installing Bowl Feeder Changeover Parts" on page 7-13.
Changeover Kit for Taper

Device ID
1005 1505 1206 2010 2512
Device Size
.050 x .103 .050 x .150 .065 x .125 .100 x .205 .125 x .260
Tape Track Label

1005E .050 x .0103 1505 .050 x .0150 1206E .065 x .125 2010E .100 x .208 2512K .125 x .206
Tape Track
TAPE-966 TAPE-963 TAPE-962 TAPE-964 TAPE-965
Seal Head Blade

8mm TAPE-869 8mm TAPE-869 8mm TAPE-869 12mm TAPE-872 12mm TAPE-872
Cover Tape Guide

Decelerator Block
Changeover Kit for Bowl Feeder

Device ID
1005 1505 1206 2010 2512
Device Size
.050 x .103 .050 x .150 .065 x .125 .100 x .205 .125 x .260
Discharge & Inline Track

1005E .050 x .0103 & .0150 1005E .050 x .0103 & .0150 1206E .065 x .125 2010E .100 x .208 2512K .125 x .206
Dead Nest
700-485 .050 x .100 700-490 .050 x .150 700-491 .065 x .125 700-492 .100 x .205 700-493 .125 x .260
Pickup Tip
CNT200-000 (round) CNT200-000 (round) CNT200-000 (round) CNT200-001 (square) CNT200-001 (square)
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Powering Up the System

Before you power up the system: 1. Make sure the system has been properly mounted on a secure table top. 2. Make sure the daily maintenance has been performed. (See Chapter 8.) 3. Check that all power cables, connecting cables, monitor, mouse, and keyboard are plugged in. 4. Check that the air regulator is on and has the correct pressure. 5. Close and latch all covers. 6. Check that the EMO (emergency stop) button is pushed in. To power up the system: 1. Turn the Baco lockable disconnect switch on the handler clockwise to the ON position (Figure 3-3).
2. If your handler has a black power switch on the computer, turn it clockwise to the ON position. Systems attached to a cabinet have a separate computer, which is located directly behind the front door of the cabinet (Figure 3-4).
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Shutting Down the System
Leveling Feet
Figure 3-4: Powering Up the Handlers Computer
3. Press the yellow CPU reset switch button. This will power up the computer system. 4. Turn on the monitor if necessary, and at the Windows password prompt, type the username and password. Both username and password are factory-set to exatron. 5. Turn the red EMO (emergency stop) button clockwise to release it. This will power up all the system mechanics.
NOTE: On systems using an automatic air shut-off valve, it is especially important to turn on the air regulator before releasing the EMO button. If this is not done, an unpleasant but harmless noise may issue until the EMO button is depressed and released again.
Shutting Down the System

Before you turn the handler off, you must properly shut down the computer. To shut down the system: > If a process is running, click the Abort Process button in the Auto Run window. 1. Click the Exit button on the Exatron Auto Run window. 2. Click the Exit button on the Exatron main window. 3. Perform the normal Windows shutdown on the handler computer: Click the Start button in the lower left corner of the screen. Click Turn Off Computer.
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Figure 3-5: Shutting Down Windows from the Start Button
4. In the Turn Off Computer dialog box, click Turn Off.
Figure 3-6: Selecting the Turn Off Option
> The yellow CPU button light will go off when Windows has shut down. 5. You can leave the black power switch turned on. 6. Push in the red EMO (emergency stop) button. 7. If the handler is equipped with a Baco lockable disconnect switch, turn it counterclockwise a quarter turn to the OFF position.
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Setting Up a Taper
Leveling Feet
Setting Up a Taper
Your handler is equipped with a Model 202 taper. Supply reel with sealing tape Empty/ out-ofpocket image sensor Output or takeup reel
Tape trackcounterclockwise direction
Supply reel with carrier tape

Figure 3-7: Model 202 Fixed-Width Taper
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Include the following procedures in your setup. Task

Mounting a Takeup Reel Mounting a Supply Reel Replacing the Tape Track Loading the Carrier Tape Loading the Sealing Tape Adjusting Seal Head Setting Temperature for Heat Seal Head
Page
3-8 3-9 3-9 3-12 3-14 3-18 3-25
Mounting a Takeup Reel

To mount an empty takeup reel: 1. Loosen the thumbscrew on the locking hub of the takeup wheel drive shaft located on the extreme left of the taper (Figure 3-8). Remove the hub and place an empty takeup reel onto the drive shaft. 2. With the three hub pins aligned to the three pinholes in the center of the reel (Figure 3-8), slide the locking hub over the reel and back into place. 3. Tighten the thumbscrew to lock the takeup reel in position.
Figure 3-8: Locking Hub on Takeup Reel with Alignment Pins
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Setting Up a Taper
Mounting a Supply Reel
Mounting a Supply Reel

Slide the carrier tape supply reel onto the three center prongs of the supply wheel so that the carrier tape unwinds from the bottom of the reel toward the right (Figure 3-9).
Figure 3-9: Center Prongs of Supply Reel
Replacing the Tape Track

If you change to a different device size, you may need to replace the tape track and possibly the seal head blade. For seal head blade changeover instructions, see "Understanding Blade Sizes and Orientation" on page 3-18 and "Changing Seal Head Blade" on page 3-19.
Figure 3-10: Changeover Tape Tracks
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Changeover Kit for Taper

Device ID
1005 1505 1206 2010 2512
Device Size
.050 x .103 .050 x .150 .065 x .125 .100 x .205 .125 x .260
Tape Track Label

1005E .050 x .0103 1505 .050 x .0150 1206E .065 x .125 2010E .100 x .208 2512K .125 x .206
Tape Track
Seal Head Blade

Cover Tape Guide

Decelerator Block
To replace the tape track: 1. Turn off the air regulator. 2. Unscrew and remove the two screws on the side of the tape track (Figure 3-11). 3. Remove the air hose (Figure 3-11, right) by pushing up and holding the orange ring and pulling down on the vinyl air hose.
Figure 3-11: Screws on Side of Tape Track to Be Removed
4. Loosen the screw on the cover tape guide block assembly and push it to the left (Figure 3-12). 5. Slide the track out to the side and remove. 6. Slide in the new tape track.
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Setting Up a Taper
Replacing the Tape Track
7. Screw in the two track screws. 8. Insert the air hose into the fitting.
Figure 3-12: Cover Tape Guide Block Assembly Pushed Left
> If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-13).
Figure 3-13: Guide Block Partly Removed from Rod
9. Adjust the guide block to fit directly over the carrier tape and sealing tape. 10. Push the guide block down so that it is flush against the carrier tape.
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11. While holding the thin edge down, tighten the adjustment screw on the guide block assembly (Figure 3-24).
Loading the Carrier Tape

To load the carrier tape: 1. Feed the leading end of the carrier tape (the leader) toward the sealing tape guide as shown above, making sure that the rear edge of the tape is under the guide at the rear of the track.
Figure 3-14: Carrier Tape Under Guide At Bottom Rear of Track
2. Push it toward the front of the underside of the tape track. Until it gets to the front, there are no more guides to thread it through. You can see the tape slack under the track. 3. At the bottom front is another guide. Thread the tape through it. 4. Bring the tape to the top side and thread it through the guides.
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Setting Up a Taper
Loading the Carrier Tape
Figure 3-15: Carrier Tape Under Guide At Top Front of Track
5. Continue feeding the carrier tape leader under the sealing heads. The sealing heads should be raised above the level of the carrier tape at this point. 6. When the carrier tape leader in the track reaches the pressure roller block, raise the top screw with your index finger and hold it while you push the keeper pin to the right, into the pressure roller block. This holds the pressure roller block in the raised position while you feed the carrier tape along the track underneath.
Figure 3-16: Lifting Pressure Roller Arm and Pushing In Keeper Pin
7. Feed the carrier tape under the projecting takeup arm. Insert the carrier tape leader into the takeup reel according to the manufacturer's specifications. Wind the carrier tape around the takeup reel until it is secured in place. The carrier tape should move freely back and forth underneath the takeup arm.
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Figure 3-17: Tape Under Takeup Arm
8. Let down the pressure roller block by slowly pulling the keeper pin out to the left until the pinch roller is lowered and just the right pressure on the tape.
Loading the Sealing Tape

To load the sealing tape: 1. Sandwich a roll of sealing tape between the two sealing tape plates, making sure the roll is snugged around the larger raised circle on the inside (Figure 318).
Figure 3-18: Sealing Tape PlatesOutside (Left), Inside (Right)
2. Suspend the reel on the sealing tape supply reel rod in the center of the taper between the two blue delrin supply reel adjustment collars (Figure 3-19), with the tape coming off the bottom of the reel.
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Setting Up a Taper
Figure 3-19: Adjustment Collar on Sealing Tape Supply Reel
3. Viewing from above, position the sealing tape supply reel centered over the carrier tape in the carrier tape track. Tighten the adjustment set screw on each supply reel adjustment collar to secure the sealing tape supply reel in this position on the rod. 4. As shown in Figure 3-20, the sealing tape unwinds from the bottom of the reel in a counterclockwise direction toward the sealing tape guide assembly. Thread the tape over the large pin and down into the guide block (Figure 3-20).
Figure 3-20: Model 202 Sealing Tape Threaded to Sealing Tape Guide Assembly (Left); Sealing Tape Threaded Under Guide Block (Right)
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> Guide blocks come in widths from 8 mm to 56 mm. There are two sets of grooves on the underside of the guide block. The outer set of grooves guides the carrier tape. The inner set of grooves guides the sealing tape.
Figure 3-21: Two Widths of Guide BlocksTop View (Left); Bottom View (Right)
Figure 3-22: Placement in Grooves of Guide Blockof Sealing Tape (Left) and Carrier Tape (Right)
5. Check to make sure the guide block is the right width for the tape you are using. 6. Loosen the side screw on the guide block assembly. > If you need to change the guide block, slip it off the guide rod and replace the new guide block on the rod (Figure 3-23).
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Setting Up a Taper
Figure 3-23: Guide Block Partly Removed from Rod
7. Adjust the guide block to fit directly over the carrier tape and sealing tape. > Push the guide block down so that it is flush against the carrier tape. > While holding the thin edge down, tighten the two adjustment screws on the guide block assembly (Figure 3-24). The carrier tape should now be inside the outer set of grooves on the guide block.
Figure 3-24: Guide Block Assembly
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8. Use light pressure or heat to attach the sealing tape to the carrier tape. CAUTION: Do not use adhesive tape on the carrier tape, as it contains static electricity and can ruin the static-free condition of the carrier tape. 9. Feed the sealing tape under the guide block assembly. Advance the tape until approximately five inches of sealing tape extends past the sealing heads. The sealing tape should now be in between the inner set of grooves on the guide block.
Adjusting Seal Head

Several adjustments may need to be done for a seal head: lateral alignment, downward pressure, and speed of descent and ascent of seal head. Correct lateral alignment assures that the seal heads are on the sealing edges of the tape; correct pressure balances the degree of heat needed to seal without tape damage. Additionally, the sealing blade will need to be changed on occasion.
Understanding Blade Sizes and Orientation

Common tape widths are shown below, with part numbers for the corresponding seal head blade and cover tape guide. Size
8 mm 12 mm 16 mm
Type
Heat seal Heat seal Heat seal
Part Number
TAPE-869 TAPE-872 TAPE-873
Cover Tape Guide Part Number

TAPE-680 TAPE-766 TAPE-723
Figure 3-25: Two Sizes of Heat Seal Blades: 16mm, Top, and 12mm, Bottom
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Setting Up a Taper
Adjusting Seal Head
Notice in Figure 3-25 that whereas different blade sizes are the same length, the spacing of the runners is what determines the width in millimeters. The runners on the top blade are spaced 16 mm apart, while the runners on the bottom blade are spaced only 12 mm apart. Pressure seal blades
Heat seal blades

Figure 3-26: Top Side of Blades As They Slide into Seal Head (Left); Bottom Side of Blades That Contact Tape (Right)
Changing Seal Head Blade

You need to change the blade in the bottom of the seal head in two circumstances: You are changing tape width to accommodate a different size of devices. You are changing between heat and pressure sealing tape. To change the seal head blade: 1. To remove the blade, insert a screwdriver as shown in Figure 3-27 and push up on the movable screw and hold it. Pull the blade out to the left as shown.
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Figure 3-27: Replacing Heat Seal Head Blade
Figure 3-28: Seal Head with Empty Rails for Blade Insertion (Back View)
2. To insert a different blade, insert a screwdriver as shown in Figure 3-27 and push up on the movable screw and hold it. Slide the blade in from the left with the smooth side up and the dowel hole toward you (Figure 3-29), then release the screw. 3. Center the blade under the seal head, sliding it back and forth until you can hear it snap and feel it catch.
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Setting Up a Taper
Adjusting Seal Head
Figure 3-29: Pressure Seal Blade Inserted Partway into RailTop View (Left), Side View (Right)
Notice that the blade must be inserted with the smooth side up and the hole out toward the operator (Figure 3-29, left). When it is slid into the rails of the seal head, it does not touch the surface of the tape track (Figure 3-29, right).
Adjusting Seal Heads Lateral Position

Use this procedure to align the lateral position of the seal head. This should need to be done very seldom; only when changing tape width by a large amount. To align lateral position of the seal head: 1. Make sure the heater is off and that the thermal heads are cool. 2. Loosen slightly but do not remove the six screws on the back side of the taper that are connected to the seal head (Figure 3-30). 3. Turn the red thumbscrew for small adjustments to move seal head away from taper base. Push gently with hand to move seal head closer to taper base.
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Figure 3-30: Six Lateral Adjustment Screws for Seal Head; Thumbscrew for Small Adjustments
4. Retighten the six screws. 5. Once the head is aligned, turn the heat to the sealing head back on. Set the temperature on the heater to the desired heat. Wait until the display has stabilized. WARNING! Do not touch the heat seal heads directly when the heat is turned on. 6. After the sealing head has warmed up, check the seal on the sealing tape. Manually engage the seal head. Apply pressure to the sealing tape for 3 to 5 seconds. Use the takeup arm to engage the head. This should cause a good seal to the carrier tape. Manually advance the carrier tape and inspect the seal. 7. Run the carrier tape for several pockets with the seal head engaged. NOTE: You may need to practice this adjustment a few times by running the machine briefly at the start of a job and inspecting the seal for quality.
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Setting Up a Taper
Adjusting Seal Head
Figure 3-31: Example of Good Tape Seal
Adjusting Seal Heads Downward Pressure

You may need to adjust the pressure of the seal head. This pressure is controlled by the auxiliary air regulator on the back side of the tape track. To adjust pressure of seal head: Pull out the black adjustment valve just below the seal head. > Turn the valve clockwise to increase the pressure. > Turn the valve counterclockwise to decrease the pressure. 8. Push the black adjustment valve back in to lock it when you have finished the adjustment.
Adjustment valve
Figure 3-32: Auxiliary Air Regulator for Seal Head Pressure
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Adjusting Speed of Seal Head

For lighter weight and smaller devices, the descent and/or ascent of the seal head may need to be slowed, to prevent devices from bouncing out of the tape pockets. See Figure 3-33. To change the upward speed of the seal head, adjust the outward-facing air flow control adjustment knob on the seal head. To change the downward speed of the seal head, adjust the right-facing air flow control adjustment knob (the one closest to the image sensor) on the seal head. To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob. 2. Turn the air flow control adjustment knob: > Turn the knob clockwise to lessen the air flow and slow the speed of the seal head, or... > Turn the knob counterclockwise to increase air flow and quicken the speed of the seal head. 3. When air flow is appropriate, turn the lock nut clockwise to tighten it.
Adjustment knob Lock nut

Figure 3-33: Outward-Facing Knob Adjusts Upward Speed; Right Knob Adjusts Downward Speed
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Setting Up a Taper
Setting Temperature for Heat Seal Head

The displayed temperatures are the actual or current temperatures. The temperature displays may be set to show Celsius or Fahrenheit. In Figure 3-34, the top left display is adjusting its temperature, as shown by the small 1 in the upper left corner above the C. In contrast, the temperatures in the other three displays are stable, because there is no number above the C or F. Also, the top left display is hot, whereas the other three displays are room temperature.
Figure 3-34: Heater Controller Displaysin Celsius (Left), in Fahrenheit (Right)
A general guideline may be to use somewhere around 275 to 325 degrees Fahrenheit for a heat seal. A narrow carrier tape takes a lower temperature to prevent burning. If in doubt, it is better to start with a lower temperature and test it, then increase little by little as needed. To set the temperature: On the Taper window of Exatron Diagnostics, set the temperature to the desired temperature (in Celsius) and then click the Set Temperature button. Temperature in Fahrenheit
77 275 300 325 350
Temperature in Celsius
25 135 149 163 177
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However, be aware that the Exatron software settings will override any different settings manually set. To turn off the heat seal head: On the Taper window of Exatron Diagnostics, set the front and back temperatures to 25 degrees Celsius and then click both Set Temperature buttons.
Getting Acquainted with the Main Window

The buttons on the Main window are described below.
Figure 3-35: Main Window
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Verifying the Factory-Installed Job File
. Buttons on Main Window Button Function Diagnostic Open a window with tabs to access various software settings and diagnostic procedures. For More Information Chapter 4
Auto Mode Open a window to do a production job in Auto Run.
page 5-2
Change Password Change a password.
page 3-31
Exit Close the Exatron software.
Verifying the Factory-Installed Job File

A job file contains the distances each part of the handler must move to get to various destinations, the number of trays, the delay times, and other settings related to the movement of the devices through the system. The job file is different from a log file; the job file does not record passes and fails or any other results data from a tester or other peripheral. The procedures for verifying the settings of your factory-installed job file and building a new job file are similar. When building a new job file, it is better to copy an existing, proven file, and modify it. To verify your file, just check the settings and distances, and make changes wherever needed. This section discusses each part of this procedure: Task Copying the factory-installed job file to modify Opening the modified job file Page 3-28 3-29
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Copying the Job File for Modifications

Exatron recommends that you save the factory-preset job file under a new name before you begin to work with it, to prevent making accidental changes to the original file. To save a job file with a new name: 1. Right-click the Start button at the bottom left corner of your Windows screen. 2. Click Explore. Windows Explorer opens.
3. In Explorer, find the Exatron folder directly under the C drive, thus: C:\Exatron. Double-click it to open it.
4. Find the job file. It has the filename extension of .job or .edf (Exatron data file). 5. Right-click on the job file. A context menu opens. 6. Click Copy on the context menu.
7. Deselect the job file name by clicking somewhere else on the screen. 8. Right-click on the screen. A context menu opens.
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Opening a Job File
9. Click Paste on the context menu.
10. Scroll to the bottom of the screen and find the copied file. Its name is Copy of ___.job or Copy of ___.edf. 11. Click once on the file to select it.
12. Click inside the filename. The cursor appears, indicating that you can retype the name.
13. Type a new name.
14. Press the Enter key on your keyboard. Now the copy has a new name. Make any modifications to this copy. Make sure the file is saved to the Exatron folder.
Opening a Job File

The Exatron software should open upon system startup. If it does not, double-click the Exatron icon on the desktop. The main window opens. To open a job file: 1. On the main window, click the Diagnostic button.
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Figure 3-36: Entering Password
2. Enter the correct password. The factory-set password is P1. This may be changed at any time with the Change Password button. 3. Inside the dialog box, open the file containing the factory presets.
Figure 3-37: Opening a Job File
CAUTION: It is strongly recommended that you dont make changes to the factoryset job file. If you need to make changes, first make a backup copy of the original job file, and experiment with the copy.
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Fine Tuning Overview
The job file that came with your handler has been preset to fit the configurations you specified. You may want to verify the settings and distances in the job file before you begin a production job in Auto Run. Use Exatron Diagnostics explained in this chapter to do so.
Fine Tuning Overview

The following procedure is to be used only as a quick reference. Before performing this procedure for the first time, please read the sections under "Fine Tune Window" on page 4-19. To fine-tune any position: 1. Select the position from the Selections drop-down box. 2. Type the approximate distance of the position from the motors zero position. 3. Type the scale by which you want to jog the motor. 4. Click the Move To button to move the motor to the position selected. 5. Click either of the jog arrow buttons (left or right; up or down) to jog the motor away from the position shown, by the scale shown.
Saving the Job File

There are two ways to save a job file. If you click the Save Parameters button on any window, the changes are saved to the job file that is currently open. If you click the OK button at the bottom right of any window, a dialog box opens that allows you to save changes under a new file name. > Make sure the file is saved to the Exatron folder. Click the Save button. To discard changes without saving, click the Cancel button at the lower right of the window.
Changing the Password

To make access to your machine secure, you can change the password initially or periodically. To change the password: 1. On the Exatron main window, click the Pwds button. 2. In the Change Passwords dialog box, type the current password in the Old Password box.
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3. Type it again in the Re-type the Old Password box to confirm. 4. Type the new password in the New Password box. 5. Type it again in the Re-type the New Password box to confirm. Click OK.
Figure 3-38: Changing Password
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Chapter Overview
This chapter describes diagnostic tasks for the Model 7000-BPR, accessed by clicking the Diagnostic button on the main window.
Figure 4-1: Main Window
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Keeping Your Original Job File

The settings displayed come from the file you opened at the beginning of the diagnostic session. If you opened the file containing the factory presets, you will likely not need to change the factory settings unless a piece of hardware or a configuration is changed. If you do need to make changes for any reason, it is recommended that you copy the file containing the factory settings first, then use the settings in the copy of the file as a basis for fine-tuning the measurements. Save any changes under a new file name. For information on copying and saving a job file, see "Copying the Job File for Modifications" on page 3-28 and "Saving the Job File" on page 3-31. The distances for each device size need to be fine-tuned only once. If you use various device sizes, set up a separate job file for each device.
Diagnostics Windows
The windows available from the Diagnostic button allow every mechanical and electrical action of the handler to be checked and tested. Usually, best results are obtained when the windows are used in order, from left to right. However, there may be occasions when it is feasible to use the features of just one or two of the windows. The following are the windows available from the Diagnostic button. Your handler has only the ones used in your setup. You can access each of the Diagnostics windows by clicking on its tab at the top of the screen. Window USB Sensor/Solenoid Check Motor Sensor/Solenoid Check Fine Tune Taper (Optional) Function Tests signals between hardware and software Sets or displays speeds of various motors; tests motor movements Sets information about tape; sets reel motor speeds Sets distances between motor positions and device destinations Sets information about tape; sets reel motor speeds Page 4-4 4-10 4-14 4-19 4-34
To access the Diagnostics windows: 1. On the main window, click the Diagnostic button. 2. Enter the correct password. The factory-set password is P1 (Figure 4-2).
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Diagnostics Windows
Figure 4-2: Entering Password
> The Load Job dialog box is displayed (Figure 4-3). 3. Open the file you need to check or modify.
Figure 4-3: Opening a Job File for Diagnostics
The first window displayed is the USB Sensor/Solenoid Check window. At the bottom right of most tabbed windows in Diagnostics are two functioning buttons.
Figure 4-4: Buttons on Each Diagnostic Window
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Save
Clicking this button saves any changes to the current job file. To save settings under a new file name, click this button. It exits Diagnostics and displays the Save As dialog box, where you are given a chance to save your changes under a new file name.
Back to Main
Clicking this button exits Diagnostics and returns to the main window without saving any changes.
USB Sensor/Solenoid Check Window

The USB Sensor/Solenoid Check window is divided into the Input and Output group boxes, where you can test the inputs and outputs.
Input Group Box

The inputs allow you to test the functioning of each sensor in the system. It tests: The sensor state Whether the software recognizes the sensors change in state You can manually block or actuate each sensor, and the corresponding checkmark or light should toggle. See the sensor manufacturers manual for more information on the sensors.
Output Group Box

This tests signals from the Exatron software to the handler. It allows every solenoid and light in the system to be tested. Placing a check mark in each check box should activate the corresponding solenoid or light.
Features on All I/O Pages

This group box checks the movement of the rotary motor against the I/O.
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Features on All I/O Pages
Figure 4-5: Test Rotary Motor and I/O Group Box
Number of Cycles
Type the number of cycles or repetitions the motor is to perform. The current cycle the motor is running is displayed. The number of times the carrier 1 sensor has detected the carrier 1 gate being retracted on the sort wheel is displayed. The number of times the carrier 2 sensor has detected the carrier 2 gate being retracted on the sort wheel is displayed. Type the number of milliseconds after one cycle finishes and the next cycle begins. Click this button to start the output sort wheel cycling. Click this button to start the pickup wheel cycling. Click this button to turn off all the motors. Click this button to start checking the inputs. Click this button to stop checking the inputs. Type the delay, in milliseconds, between the command to open each output carrier gate and the command to close the carrier gate.
Current Cycles Sensor Count 1
Sensor Count 2
Delay Between Cycles
Run Sort Wheel Motor Run Pick Wheel Motor All Motors Off Start Checking Stop Solenoid On Delay
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Selecting a Board to Check

Each port page gives access to a different group of inputs and outputs. Your handler may have two or three boards of ports.
Figure 4-6: Port Selection Drop-Down List
Select Board
Click the dropdown arrow to the right of the box, and click the port page you want to access.
Board 1Output Sort Wheel Carrier Positions
Figure 4-7: USB Sensor/Solenoid Check WindowBoard 1
Outputs
Carry [n] Solenoid Check each box to activate the corresponding output carrier gate. Uncheck each box to undo the action.
Inputs
Carry [n] Sensor Each box turns green when the corresponding output carrier gate is retracted.
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Board 2Motor Home and Present Sensors
Board 2Motor Home and Present Sensors
Outputs
You can check the Dead Nest Vac or Dead Nest Air Blow output box to turn on the vacuum or blow-off at the bowl feeders dead nest. You can check the RUN or HALT output box to light the corresponding button. You can check the Red, Yellow, or Green output box to make the corresponding light pole light turn on.
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Inputs
Input Pick Motor Home Test Motor Home Dead Nest Sensor Tape Motor Home Interlock Pick Wheel Motor RUN HALT Bucket [1-8] Present Box Is Green When... Z pusher motor over bowl feeder is at home position Z pusher motor over test site is at home position Device is present in the bowl feeders dead nest Z pusher motor over taper is at home position Cover is open Pickup wheel is moving RUN button is not depressed HALT button is not depressed The corresponding smart bucket is present in its slot.
Board 3Z Pickup Nozzles Vacuum and Blow-Offs
The Z heads are numbered in a counterclockwise direction. Thus, when Z1 is at the bowl feeder dead nest input, Z2 is at the taper, Z3 is at the drop-off to the output sort wheel, and Z4 is at the test site.
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Board 3Z Pickup Nozzles Vacuum and Blow-Offs
Outputs
Output Z[n] Vacuum Z[n] Air Blow Check Box To... Turn on vacuum at the specified nozzle Turn on air blow at the specified nozzle
Inputs
Input Z[n] Vacuum Sensor Box Is Green When... No device is attached to the specified nozzle
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Motor Window
This window sets or displays the speed of the various motors and tests motor movements. The settings on this window allow you to move the motors manually. This is a way to test, exercise, and clean the motors. You can select the motor you want to test. CAUTION: Before you move the motor positions, make sure there is no interference that will produce a collision. You can also use this window to turn off one or all motors. When a motor is turned off, the assembly it controls is freely movable by hand. Thus, you can move an assembly out of the way to perform inspections or repairs. To turn the selected motor back on, click the Motor On button; or to turn all motors back on, click All Motors On.
Figure 4-10: Motor Window
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Motor Window
Motor List Group Box
Motor List Group Box
Figure 4-11: Motor List Group Box
Motor List
To view the timings for a motor, click the drop-down arrow by the Motor List box, and select the motor. Most actions you initiate on this window apply to the motor you select in the Motor List.
Motor On
Click this button to send all the tray carriage and pickup head motors to their home positions. If the motors have been turned off, click this button to turn them back on. Click this button to turn off all the tray carriage and pickup head motors.
Motor Off
Motor Settings Group Box

This matrix displays the speeds of the motors as they move through production in Auto Run. For details, see the motor manufacturers manual. CAUTION: Changing motor settings may cause damage to the handler and devices.
Figure 4-12: Motor Settings Group Box
Speed AC DC COM
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The speed for each motor is displayed. The acceleration for each motor is displayed. The deceleration for each motor is displayed. The COM port for each motor is displayed.
4-11
Home Sequence Group Box
Figure 4-13: Home Sequence Group Box
Motor Home
Click this button to move the selected motor to its home position. Click this button to stop the test cycle immediately, before the cycle is finished. Click this button to turn off the selected motor, enabling the corresponding component to move freely. Thus you can adjust its position manually.
Abort
Motor Off
Test Motor Group Box

This group box allows the operator to perform stability tests on the selected motor.
Figure 4-14: Test Motor Group Box
Position 1
Type a beginning position from home for a test cycle. If one of the 3 pusher motors (pick, test, or tape) is selected in the Motor List, the distance should be typed in inches.
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Motor Window
If one of the 2 rotary motors (pick wheel or sort wheel) is selected in the Motor List, the distance should be typed in motor steps. Go Position 2 Click this button to move the motor to Position 1. Type an ending position from home for a test cycle. If one of the 3 pusher motors (pick, test, or tape) is selected in the Motor List, the distance should be typed in inches. If one of the 2 rotary motors (pick wheel or sort wheel) is selected in the Motor List, the distance should be typed in motor steps. Go Repeat Start Click this button to move the motor to Position 2. Type the number of times you want the test cycle to repeat. Click this button to begin the test cycle with the specified number of repeats to the two set positions. This box incrementally displays the number of repeats that have finished during the test cycle. Click this button to stop the test cycle immediately, before the cycle is finished.
[Count]
Abort
Save
If you want to save your changes to the job file you opened when you entered Diagnostics, click this button.
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Sensor/Solenoid Check Window

The Sensor/Solenoid Check window is divided into the Input and Output group boxes, where you can test the inputs and outputs. You can also load an inspection file to the camera with the P2 outputs.
Figure 4-15: Sensor/Solenoid Check Window
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Inputs
Inputs
Input Empty, Out of Pocket, Tape Inspection Gap EMO Interlock Heater Alarm Slack Switch Tape Out Error Box Is Green When... Pocket under sensor is not empty Gap sensor cannot see through pocket hole EMO button is not activated Present value and set value are same temperature Tape is not taut and takeup arm is down Tape is not out; continuing tape supply
Outputs
For a more detailed explanation of loading an inspection file to the camera, see the next section, "Loading an Inspection File to the Camera" on page 4-15. Output Seal Head Tape Vacuum Take Up Motor Camera Trigger Load Inspect Job Ins Job Bit 0 Ins Job Bit 1 Ins Job Bit 2 Lower seal head Turn on carrier tape vacuum under the pickup head drop site; helps to seat devices in pocket Turn on takeup reel Trigger a single inspection Load the inspection file specified in the following 3 boxes Switch the binary bit in the 0 position to a high signal to load an inspection file to the camera Switch the binary bit in the 1 position to a high signal to load an inspection file to the camera Switch the binary bit in the 2 position to a high signal to load an inspection file to the camera Check Box To...
Loading an Inspection File to the Camera

A three-bit high/low signal is sent to the camera (image sensor) to specify the inspection file to load. The binary digit positions are counted from right to left: bit 0, bit 1, and bit 2. A 1 in a bit position sends a high signal; a 0 in a bit position sends a low signal. With three digits, eight
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combinations are possible, with each one indicating an individual inspection file. Only five inspection files are shipped with the handler, leaving the potential for three more files in the future. Bit 2 Position
0 0 0 0 1 1 1 1
Bit 1 Position
0 0 1 1 0 0 1 1
Bit 0 Position
0 1 0 1 0 1 0 1
Combined Binary Number

000 001 010 011 100 101 110 111
Inspection File for Device Size

1005 1206 1505 2010 2512 for future use for future use for future use
Inspection Job Number

1 2 3 4 5
Thus, the boxes checked correspond with the binary digit positions. A checked box sends a 1 or high signal; an unchecked box sends a 0 or low signal. Thus, if the Ins Job Bit 0 box is checked but the other two are not checked, the signal sent is 001, where bits 2 and 1 are zeros and bit 0 is 1.
Binary signal 000 for file 1005
Figure 4-16: Bit Settings for Inspection Files 1005, 1206, and 1505
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Taper Override Buttons
Figure 4-17: Bit Settings for Inspection Files 2010 and 2512
After you have set the bits by checking the appropriate Ins Job Bit boxes, then check the Load Inspect Job box to load the specified inspection file to the camera.

The tapers override buttons are on the taper control panel, on the side of the taper box.
Taper Solenoid Override Buttons

Button White Blue Yellow Green Affects Seal head Output 1 Takeup reel Output 3 Action When pressed, the seal head is lowered Spare button for extra options When pressed, the takeup reel motor is activated, turning the reel Spare button for extra options
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Sensor lights
Override buttons
Figure 4-18: Taper Control Panel with Sensor Lights and Override Buttons
Gap sensor
Figure 4-19: Taper with Image Sensor (Left) and Gap Sensor (Right)
The image sensor checks for a device present and properly seated in the tape pocket. If a device is missing from the tape pocket, the taper stops. The Gap sensor is located in front of or to the right of the pickup heads drop point for the taper. It finds the home position for the tape and ensures correct offset after homing.
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Fine Tune Window
Fine Tune Window

When you click the Diags button on the main window, the motors reset. You see the message: Machine will be reset first. When all the motors have moved to their home positions, this window becomes available.
Figure 4-20: Fine Tune Window
To refer to a specific area of this window, find the group box in the following list. Group Box or Area
Sort Wheel Motor Position Group Box Pickup Wheel Motor Position Group Box Messages and Motors Group Box Inspection Job Group Box Increment Group Box
Page
4-20 4-21 4-22 4-22 4-23
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Group Box or Area

Delay Group Box Pickup Wheel Motor Offset Group Box Sort Wheel Motor Offset Group Box Pick Motor Group Box I/O Group Box Test Motor Group Box Drop to Carry Group Box Tape Motor Group Box
Page
4-24 4-25 4-26 4-28 4-29 4-29 4-31 4-32
Sort Wheel Motor Position Group Box
Figure 4-21: Sort Wheel Motor Position Group Box
Home with Offset
Click this button to rotate the output sort wheel to its home position, then to move the number of motor steps designated as its offset, to get to the position where carrier 1 is at the drop-off from the pickup wheel. The output sort wheels current position is displayed in relation to where carrier 1 is at the drop-off from the pickup
Current Position
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Fine Tune Window
Pickup Wheel Motor Position Group Box
wheel. (Position 0 is displayed only after first homing the wheel.) Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Go to Next Position Carrier at Pickup Wheel Drop-off 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Carrier at Bucket 1 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
Click this button to rotate the output sort wheel to the next position after the current position.
Pickup Wheel Motor Position Group Box
Figure 4-22: Pickup Wheel Motor Position Group Box
Home with Offset
Click this button to rotate the pickup wheel to its home position, then to move the number of motor steps designated as its offset, to get to the position where pickup nozzle Z1 is over the bowl feeder dead nest.
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Current Position
The pickup wheels current position is displayed in relation to where its Z1 pickup head is over the bowl feeder dead nest. Position 1 2 3 4 Pickup Head 1 Location Bowl feeder dead nest Test site Drop-off to output sort wheel Tape
Go to Next Position
Click this button to rotate the pickup wheel to the next position after the current position.
Messages and Motors Group Box
Figure 4-23: Messages and Motors Group Box
[Message display} Reset Motor Off Clear Messages
Progress or status messages are displayed here. Click this button to turn on and home all motors. Click this button to turn off all motors. Click this button to clear the message box of all messages.
Inspection Job Group Box

Click the drop-down arrow at the right of the box and select the inspection file for the desired device size.
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Fine Tune Window
Increment Group Box
Figure 4-24: Inspection Job Drop-Down
Increment Group Box

Inc/Dec Type the scale, or size, of each increment or decrement by which a motor should move when one of the jog buttons is clicked. For example, if the value here is 0.005 and the value in one of the distance boxes is 0.505, then when the Increase Distance or left jog button for that distance box is clicked, the value changes to 0.510. Other examples follow. Current Value 0.365 0.96 Wheel Motor Scale (Step) Incremented Value 0.370 0.965 Decremented Value 0.360 0.955
Type the number of motor steps by which a rotary motor should move when one of the offset jog buttons is clicked.
Dead Nest Air/Vac Group Box
Figure 4-25: Dead Nest Air/Vac Group Box
Enable Taper
Check this box to use the taper as a sort 1 output. Uncheck this box to not use the taper as an output.
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Enable Dead Nest Airblow Check this box to use the air blow at the bowl feeder to push devices down the inline track to the dead nest. Uncheck this box to disable the air blow at the bowl feeder. Enable Dead Nest Vacuum Check this box to use the vacuum at the bowl feeder to stabilize devices in the dead nest. Uncheck this box to disable the vacuum at the bowl feeder dead nest.
Delay Group Box
Figure 4-26: Delay Group Box
Vacuum On
After issuing the command to turn on the vacuum, the handler waits the number of milliseconds shown before giving the next command (to check the vacuum sensor to see if a device is attached to the pickup head). After issuing the command to turn off the vacuum, the handler waits the number of milliseconds shown before giving the next command (to turn on the air blower). After the vacuum is turned off, this is the number of milliseconds the air blow-off stays on to blow a device off the pickup head at the drop-off to the output sort wheel. After issuing the command to turn off the air blow-off at the drop-off to the output sort wheel, the handler waits the number of milliseconds shown before giving the next command (to move the pickup head). After issuing the command to turn off the vacuum at the dead nest, the handler waits the number of milliseconds shown before giving the next command (to pick the device from the dead nest). After issuing the command to turn on the air blow-off at the drop-off to the tape, the handler waits the number of milliseconds shown before giving the next command (to raise the pickup head).
Vacuum Off
Air Blow On
Air Blow Off
Delay After Dead Nest Vacuum Off
Air Blow at Taper
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Fine Tune Window
Pickup Wheel Motor Offset Group Box
Pickup Wheel Motor Offset Group Box

The pickup wheel rotary motors home position does not place the pickup heads directly in line with the key positions (input, test, and outputs). Therefore, an offset distance needs to be specified from the home position to where the Z1 pickup is at the bowl feeders dead nest pickup site. This offset distance is slightly different for large and small devices.
Figure 4-27: Pickup Wheel at Home Position (Left); Moved to Offset (Right)
Figure 4-28: Pickup Wheel Motor Offset Group Box
Home Without Offset
Click this button to rotate the pickup wheel to its home position. In the input box, type the number of motor steps the pickup wheel must move from its home position to where the Z1 pickup is at the bowl feeders dead nest pickup site. Click this button to rotate the pickup wheel to where the Z1 pickup is at the bowl feeders dead nest pickup site. If the alignment is off, make any small adjustments by clicking the left or right jog buttons. The pickup wheel rotates by the distance shown in the Scale input box, and the number shown in the Distance input box changes accordingly.
[Offset]
Go to Offset
[Left/Right]
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Sort Wheel Motor Offset Group Box
Figure 4-29: Sort Wheel Motor Offset Group Box
Home Without Offset
Click this button to rotate the output sort wheel to its home position. In the input box, type the number of motor steps the output sort wheel must move from its home position to where its carrier 1 is at the pickup heads drop-off site. Click this button to rotate the output sort wheel to where its carrier 1 is at the pickup heads drop-off site. If the alignment is off, make any small adjustments by clicking the left or right jog buttons. The output sort wheel rotates by the distance shown in the Scale input box, and the number shown in the Distance input box changes accordingly.
[Offset]
Go to Offset
[Left/Right]
Comparing the Z Distances

The Z motor is attached to the Y gantry, and drives the vertical movement of the pickup head. Z distances are measured down from Z home, which is at the top of the Z travel. These distances may vary slightly from pickup head to pickup head, and from test site to outputs. The two Z distances are: Z-pickthe distance from the Z home position to the device pickup position Z-dropthe distance from the Z home position to the device release position Z-pick picks up a device from a site, so it must be a bit closer to the surface of a device than Zdrop, which is required only to drop the device into the site. The important thing to remember is that Z-drop (the put height) for each location is higher than Z-pick (the pick height) for that same location. Thus, the Z-drop distance from Z home (at the top of Zs vertical travel) is a smaller number than the Z-pick distance. This is because closer contact is required for the pickup head to pick up a device than to drop it into the pocket. The key to defining a Z-pick distance is to have the suction cup just touching the device, but not flattened on it. The suction cup should be high enough that when you turn on the vacuum, you can see the device lift slightly against the suction cup.
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Fine Tune Window
Comparing the Z Distances
Figure 4-30: Suction Cup at Z-Pick
Notice that the suction cup at Z-pick is just touching the device, but not flattened on it.
Figure 4-31: Suction Cup at Z-Drop
Notice that the suction cup at Z-drop is not quite touching the device.
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Pick Motor Group Box

The actions in this group box apply to the distance each Z motor must move when over the bowl feeder dead nest pickup site. Be sure to click Go to Next Position in the Pickup Wheel Motor Position group box between calibrating each pickup head.
Figure 4-32: Pick Motor Group Box
[Z-pick distance]
In the input box, type the distance from the selected pickup heads home to the Z-pick position. Click this button to move the pickup nozzle down to the Zpick position shown in the Z Get Distance input box. You must click this button before you can make fine-tune adjustments with the jog buttons.
Push Z[n]
Z[n] Pick Part
Click this button to move the pickup nozzle down to the Zpick position shown in the Z-Pick Distance input box, turn on its vacuum, and raise it again with a device attached. If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets smaller by the same scale.
[Up]
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Fine Tune Window
I/O Group Box
[Down]
If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets larger by the same scale. Click this button to raise the pickup head to its Z home position.
Go to Zero
I/O Group Box

The Z1 through Z4 actions in this group box apply to the pickup nozzles currently at the four pickup/drop sites. Z1 is at the bowl feeder dead nest Z2 is at the test site Z3 is at the drop-off to the output sort wheel Z4 is at the taper.
Figure 4-33: I/O Group Box
Z[1-4] Vacuum
Check the box to turn on the corresponding Z nozzle vacuum. Uncheck the box to turn off the vacuum. Check the box to turn on the corresponding Z nozzle blowoff. Uncheck the box to turn off the blow-off. Check the box to turn on the vacuum at the bowl feeder dead nest. Uncheck the box to turn off the vacuum. Check the box to turn on the vacuum at the tape pocket. Uncheck the box to turn off the vacuum.
Z[1-4] Air Blow
Dead Nest Vacuum
Tape Vacuum

The actions in this group box apply to the distance each Z motor must move when over the test site. At the test site, the pickup nozzle pushes down and holds, then rises with the device still attached. Therefore, there are not two Z distances here, but only one. The Z-push position
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is the same as the Z-pick position. There is no Z-drop at this site. Be sure to click Go to Next Position in the Pickup Wheel Motor Position group box between calibrating each pickup head.
Figure 4-34: Test Motor Group Box
[Z-pick distance]
In the input box, type the distance from the selected pickup heads home to the Z-pick position. Click this button to move the pickup nozzle down to the Zpick position shown in the Z-Pick Distance input box. You must click this button before you can make fine-tune adjustments with the jog buttons.
Push Z[n]
[Up]
If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets larger by the same scale.
[Down]
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Fine Tune Window
Drop to Carry Group Box
Go to Zero
Click this button to raise the pickup head to its Z home position.
Drop to Carry Group Box

The actions in this group box apply to each Z pickup when over the drop-off to the output sort wheel. Be sure to click Go to Next Position in the Pickup Wheel Motor Position group box between clicking each button.
Figure 4-35: Drop to Carry Group Box
Z1 Drop Part
Click this button to turn off the vacuum and turn on the air blower for the Z1 pickup nozzle when it is over the drop-off to the output sort wheel. Click this button to turn off the vacuum and turn on the air blower for the Z2 pickup nozzle when it is over the drop-off to the output sort wheel. Click this button to turn off the vacuum and turn on the air blower for the Z3 pickup nozzle when it is over the drop-off to the output sort wheel. Click this button to turn off the vacuum and turn on the air blower for the Z4 pickup nozzle when it is over the drop-off to the output sort wheel.
Z2 Drop Part
Z3 Drop Part
Z4 Drop Part
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Tape Motor Group Box

The actions in this group box apply to the distance each Z motor must move when over the tape track. Be sure to click Go to Next Position in the Pickup Wheel Motor Position group box between calibrating each pickup head.
Figure 4-36: Tape Motor Group Box
[Z-pick distance]
In the input box, type the distance from the selected pickup heads home to the Z-pick position. Click this button to move the pickup nozzle down to the Zpick position shown in the Z-Pick Distance input box. You must click this button before you can make fine-tune adjustments with the jog buttons.
Push Z[n]
Z[n] Drop Part
Click this button to turn off the pickup nozzles vacuum and allow the device to drop into the tape pocket.
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Fine Tune Window
Tape Motor Group Box
Z[n] Pick Part
Click this button to move the pickup nozzle down to the Zpick position shown in the Z-Pick Distance input box, turn on its vacuum, and raise it again with a device attached. If the suction cup is too close to the device, raise the pickup head by clicking the Up jog button. Each time you click this button, the pickup head moves closer to Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets smaller by the same scale. If the suction cup is not close enough to the device, lower the pickup head by clicking the Down jog button. Each time you click this button, the pickup head moves away from Z home position by the distance shown in the Scale input box, and the number in the Z-Pick Distance input box gets larger by the same scale. Click this button to raise the pickup head to its Z home position.
[Up]
[Down]
Go to Zero
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Taper Window
The Taper window sets measurements and distances in relation to the tape and sets reel motor speeds. The selections under each group box are discussed together.
Figure 4-37: Taper Window
Test Group Box
Figure 4-38: Test Group Box
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Taper Window
Seal Head Temperature Group Box
Head Z List
Click the drop-down arrow to the right of the box and select the Z nozzle you want to move. Click this button to move the Y pickup head to the tape track position shown in the input box to the right. Click this button to move the pickup nozzle down to the Z-put position. Click this button to cause the pickup head to put a device in the tape pocket. Click this button to raise the Z nozzle up to its home position. Check the box to turn on the vacuum at the tape pocket. Uncheck the box to turn off the vacuum. Check the box to turn on the corresponding Z nozzle vacuum. Uncheck the box to turn off the vacuum.
Head Go To Tape Reel
Go to Put Height
Put Device To Tape Reel
Z Home Tape Vacuum
Z Vacuum
Seal Head Temperature Group Box

The temperature set here for the heat seal head overrides any manual settings made on the heater controller itself. The input temperature must be in Celsius. Following is a short conversion table that can be used as a rough reference. Temperature in Fahrenheit
77 250 275 300 325 350
Temperature in Celsius
25 121 135 149 163 177
Figure 4-39: Seal Head Temperature Group Box
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Set Temperature Current Temperature
Type the desired sealing temperature. After you click Read Temperature, the current sealing temperature is displayed. Click this button to start the heater heating to the set temperature. Click this button to display the current temperature.
Set Temperature
Read Temperature
Delay Group Box

Z Put Delay After issuing the command to move the pickup head to the Zdrop position, the handler waits the number of milliseconds shown before giving the next command (to turn the vacuum off). Type the number of milliseconds after the seal head goes down to the tape before the tape is moved.
Seal Head Down Delay (msec)
Motor Group Box

These parameters apply to the taper motor.
Figure 4-40: Motor Group Box
Speed AC DC (% of AC)
Type the desired motor speed. Type the acceleration speed. Type the deceleration speed as a percentage of the acceleration speed. For example, if the acceleration speed is 50, and the deceleration speed should be the same as the acceleration, type 100 in the DC box, for 100 percent of the acceleration speed. If the deceleration speed should be half the acceleration speed, type 50 in the DC box.
Steps
Type the number of steps you want to move the motor. Note that 50,000 steps complete one revolution.
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Taper Window
Tape Reel Group Box
Enable Motor Motor Off Motor Go
Click this button to turn on the motor. Click this button to turn off the motor. Click this button to move the motor the number of steps displayed in the Steps box to the left.
Tape Reel Group Box
Figure 4-41: Tape Reel Group Box
Gap Offset (Steps)
Type the number of motor steps needed to move the tape from the offset position identified by the gap offset sensor to the center of the pocket. Because of various tape pocket sizes, when the tape is in position so the gap sensor "sees" through the hole in the middle of the empty pocket, the corresponding tape pocket under the pickup head is likely not centered under the pickup head nozzle. Therefore, the tape needs to be advanced the correct number of motor steps, so the pickup head can place the device into the center of the pocket and not on the pocket edge. Notice that in Figure 4-42, when the pocket is centered under the pickup head, the gap sensor is between pockets. This is the gap offset.
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Pickup head nozzle
Gap sensor
Figure 4-42: Gap Sensor Offset from Pickup Head
Initial Taper
Click this button to initialize the taper. This advances the tape until the next tape pocket hole is under the front Gap sensor. From there, it moves the number of motor steps specified in the Gap Offset (Steps) input box to get the next emptypocket hole under the pickup head, and stops. This is the homing process for the taper. After you click Initial Taper, the buttons below it are enabled.
Leader Count (# of Pockets)
Type the number of pockets needed from the back edge of the tape track to the output reel takeup spool. This is the number of empty pockets passed before the machine begins putting devices in the pockets. Click this button to advance the tape by the number of pockets specified in the Leader Count box.
Advance Leader
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Taper Window
Tape Reel Group Box
Ending point for leader count
Starting point for leader count
Figure 4-43: Leader Pockets
Trailer Count (# of Pockets)
Type the number of empty pockets to be passed after the empty pocket sensor. The tape will continue to be sealed to this number of pockets after the specified number of devices have filled the specified number of pockets for the job. Click this button to advance the tape by the number of pockets specified in the Trailer Count box.
Advance Trailer
Take-up Motor Count (# of Type the number of pockets required for the tape to go from Pockets) a slack position until the slack switch blocks the slack switch sensor and turns on the output reel motor (Figure 4-44). Abort Click this button to stop the action caused by the Advance Leader, Advance Trailer, or Advance Pockets buttons. For example, if the number of leader pockets is set at 50, and you have clicked Advance Leader, and ten leader pockets have advanced, this button aborts the tape advancement immediately at ten.
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Figure 4-44: Output Tape Slack (Left); Output Tape Taut, Raising Takeup Arm (Right)
Number of Holes Between Type the number of sprocket holes between the hole in one Pockets pocket and the hole in the pocket next to it. In the example in Figure 4-45, there are three sprocket holes between pocket centers.
Figure 4-45: Counting Number of Sprocket Holes Between Pocket Centers
Number of Pockets
Type the desired number of test leader pockets to advance (optional). Click this button to advance the tape by the number of pockets specified in the Number of Pockets box (optional).
Advance Pockets
Number of Pockets Before Type the number of pockets to be advanced after the tapeCheck Tape Out Error out error sensor first detects no tape and before the machine stops and gives a tape-out message.
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Taper Window
Taper Empty Pocket Latch Group Box
Enable/Disable Seal Head Check this box to turn on the seal head and seal the tape after inserting the devices. Uncheck this box to turn off the seal head. PSA/Thermo Select the desired option to seal with pressure-sensitive tape or thermal (heat) tape.
Taper Empty Pocket Latch Group Box

This group box allows a temporary record to be displayed of taper events that occurred. If the LED lights up but the software does not display a check in the box, then the sensor is working but has lost communication with the software. If the LED does not light up but the software displays a check in the box, then the sensor is working but the wiring connection to the taper cabinet is lost or the LED bulb is burned out. If neither does the LED light up, nor does the software display a check in the box, then the sensor is not working. Empty Pocket Latch When the Empty Pocket sensor sees through the hole in the center of the tape pocket, the LED light on the taper cabinet turns on, and the software places a checkmark in this checkbox.
Clear Empty Pocket Latch When you have finished confirming the results, click the Clear Latch button to clear the checkmarks from the latch displays. Save Parameters Click this button only if you want to save changes under the current file name. To open a dialog box so you can save changes under a new file name, click the OK button instead.
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Chapter 5: Auto Run

Chapter Overview
This chapter discusses the following main topics: Topic Halt, Run, and EMO Buttons Starting an Auto Run Auto Run Window Features Page 5-1 5-2 5-6
Halt, Run, and EMO Buttons

The EMO (emergency stop) button can be pushed in anytime there is a need to instantly disable the motors and shut off the 24-volt AC. However, it leaves the computer running, so that when Auto Run is continued, the operator is given the choice of restarting where the handler left off with the device count.
Figure 5-1: HALT, RUN, and EMO (Emergency Stop) Buttons
To release the EMO button, turn it clockwise until it pops out again.
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Chapter 5: Auto Run
The HALT and RUN buttons near the EMO button work just like the Exatron software buttons Pause or HALT and Continue or RUN in the Auto Run window. Pressing HALT pauses the handler, while it keeps count of the devices. NOTE: After depressing the HALT button, you must press HALT a second time to release it and permit RUN to be pressed. Pressing RUN resumes the Auto Run where it left off.
Starting an Auto Run

Running parts in Auto Run requires a predefined job file, as explained in "Verifying the Factory-Installed Job File" on page 3-27 and "Keeping Your Original Job File" on page 4-2. To start an Auto Run: 1. On the main window, click the Auto Mode button. > The Load Setting File dialog box is displayed (Figure 5-2).
Figure 5-2: Opening a Job File for Auto Run
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2. Select the file that corresponds with the type of device you want to run and click Load This File. The Auto Run window opens (Figure 5-3).
Figure 5-3: Auto Run Window
3. Switch to the tester computer and on the tester software main window, click either the Test Single Value Mode button or the Test Multiple Values Mode button. Load the appropriate job file. Then click the Auto Run button on the tester software. This must be done before you start a run on the handlers computer. See Chapter 6 for more information. 4. Switch back to the handler computer. On the Auto Run window in Figure 5-3, click the RUN button. > The first dialog box that opens is the Bucket Setting box (Figure 5-4).
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Chapter 5: Auto Run
Figure 5-4: Bucket Setting Dialog Box
5. Type the maximum number of devices that should be put in each of the five "GOOD" buckets. Remember that fewer large devices than small devices will fit in a bucket. Click OK. > The second dialog box that opens is the Initializing Tape and Reel box (Figure 5-5). 6. Make any desired changes to the counts, as described in the next section, "Auto Run Using Tape and Reel" on page 5-5. After you do, the Auto Run begins.
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Auto Run Using Tape and Reel
Auto Run Using Tape and Reel

When you click the RUN button on a system using a tape and reel, the Initializing Tape and Reel dialog box is displayed. The options available here enable you not to leave an empty pocket if you have had to leave Auto Run in the middle of a job. Alternatively, you can specify a certain number of empty tape pockets on one reel between jobs for various purposes.
Figure 5-5: Initializing Taper Before Auto Run
Would you like to initialize Click Yes or No. Tape and Reel? Clicking Yes has the same effect as clicking the Initial Taper button on the Taper window in Diagnostics. It homes the tape, or moves it to the Gap sensor and then to where the next empty pocket is under the path of the pickup head. Click No if you want to restart a job that is already in the correct position. The tape is not advanced before Auto Run begins. Advance Leader Counts This is the the number of empty tape pockets to be advanced at the start of the Auto Run. The default number comes from the Leader Count box in the Taper window of Diagnostics. You can type a different number of leader pockets for the cur-
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Chapter 5: Auto Run
rent run, but the changed value is not saved. The next time Auto Run is opened, the default value will be shown again. Advance Trailer Counts This is the number of empty tape pockets to be advanced at the end of the Auto Run. The default number comes from the Trailer Count box in the Taper window of Diagnostics. You can type a different number of trailer pockets for the current run, but the changed value is not saved. The next time Auto Run is opened, the default value will be shown again. The number of devices already placed in the tape is displayed incrementally. You can change this number if necessary. For example, if the number of devices previously processed in this job was 3, but the tape has advanced two empty pockets, you can manually place two passed devices in the empty pockets behind the pickup head. Then you can change the number 3 to 5, and the count will be correct again. Total Tape Counts The total number of devices to be placed in the reel of tape is displayed here. You can change this number if necessary. Click this button to start the Auto Run. Click this button to close this box and return to the Auto Run window.
Current Tape Counts
OK Cancel
Auto Run Window Features

The rest of this chapter explains the various features on the Auto Run window.
Buttons
Run Click this button to begin the processing of devices in Auto Run. This button is enabled only after a run has been started by clicking the Auto Run button. Click this button to pause the job. The handler keeps count of the devices already sorted and those to be sorted. This button is enabled only after a run has been started and the Pause button has been clicked. Click this button to restart the job where it left off. Click this button to stop the handler from searching for more devices before the number of empty pockets specified has
Pause
Continue
End of Lot
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Buttons
been reached. Any devices that remain at the test site(s) are tested, then the pickup head takes these last tested devices to their sorted destination. Then all motors are sent home. When you click this button, the Advance Trailer dialog box is displayed (Figure 5-6). If you click Yes, the tape will be advanced for the number of trailer pockets specified. If you click No, the tape will not be advanced, allowing you to restart the job where you left off. Back Advance Taper Pocket Click Exit to return to the main window. Click this button to open the Advance Trailer dialog box (Figure 5-6). Type the number of tape pockets to advance at the end of a run. Clicking Yes advances the tape and closes this dialog box. Clicking No just closes this box.
Figure 5-6: Advance Trailer Dialog Box
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Chapter 5: Auto Run
Statistics Group Box
Figure 5-7: Statistics Group Box
Total Count
As the Auto Run progresses, the number of devices sorted to each bin is incrementally displayed. As the Auto Run progresses, the total number of devices sorted to each "GOOD" bucket is incrementally displayed. When a bucket is full, the message is displayed: Bucket GOOD [1-5] reached max count. Please remove bucket. After you empty and replace the bucket, and click the Continue button, the bucket count in this column is reset to zero.
Current Count
Pre Sort 1
The number of devices previously sent to sort 1, the taper, is displayed. The total number of devices processed so far in the production run is displayed.
Total
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Auto Run Status Group Box
Auto Run Status Group Box

Initially the display is blank. As the Auto Run progresses, some messages are displayed. You can scroll up to see previous messages. You can also check the log file later. All except the initial messages are turned off for faster speed. Other panes may have messages turned on by the engineer for debugging purposes (Figure 5-8).
Figure 5-8: Auto Run Status Group Box with Full Messages Turned On
Tester Operation Group Box
Figure 5-9: Tester Operation Group Box
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Chapter 5: Auto Run
You can select the option of either real testing or simulation. If you select simulation, you can designate either all sort 1 or random sorts 1 to 8.
Start Time Group Box

The date and time the current Auto Run started is displayed.
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Chapter Overview
This chapter discusses the following main topics: Topic Operation Overview Testing Modes Accessing a Test Mode Single-Value Mode Multiple-Value Mode Page 6-1 6-2 6-3 6-4 6-8
Operation Overview
The tester computer uses a voltmeter to measure resistor values. The GPIB interface is used for communication between the tester computer and the voltmeter. A serial interface is used for communication between the tester computer and the handler computer. The resistor tester evaluates the resistance of individual chip resistors to determine whether each meets the tolerance limit by measuring the resistance and then calculating the deviation from the nominal or ideal value.
Starting the Tester Software

The tester software comes preinstalled on the system. The tester software will automatically start. If the software does not start automatically, double-click the program icon on the desktop.
Switching Between System Computers

If your system includes a peripheral that has its own computer (such as a tester or inspection camera), they may all be using one monitor and keyboard. Switch between computers by pressing the <Scroll Lock> key twice, then the Up or Down arrow key one or more times to scroll to the desired computer. If the keyboard has a Function key, use it concurrently with the Scroll Lock key.
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Testing Modes
Two modes are available upon opening the tester software: Single-Value Mode (using the Auto Run window) and Multiple-Value Mode (using the Testing Multiple Values window). In Single-Value Mode, one type and size of device is put in the bowl feeder, tested, and directed to pass or fail sorts. All the resistors have a single resistance deviation tolerance. Fail sorts are directed to bucket 3, "Reject." Pass sorts may be directed to the taper (sort 1) or to bucket 7 with the "GOOD 1" label at sort 8. In Multiple-Value Mode, devices of one size but varying resistance values are put in the bowl feeder, tested, and directed to various pass sorts, according to their electrical resistance.
Figure 6-1: Tester Main Window Buttons
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Accessing a Test Mode
Switching Between System Computers
Accessing a Test Mode

To access either testing window: 1. Click either the Test Single Value Mode button or the Test Multiple Values Mode button on the main window. > The Load Job dialog box is displayed (Figure 6-2).
Figure 6-2: Load Job File Dialog Box
2. Click the file you want to open, and click Load Job File. > If you clicked the Test Single Value Mode button, the Auto Run window opens (Figure 6-3). > If you clicked the Test Multiple Values Mode button, the Testing Multiple Values window opens (Figure 6-6).
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Single-Value Mode
The window for Single-Value mode is accessed from the Test Single Value Mode button on the main window.
Figure 6-3: Auto Run Window
Batch Group Box

Production Number Nominal Value in Ohms Tolerance (in %) Type the production number for this run. Type the nominal or ideal electrical resistance in ohms. Type the tolerance limit in percentage.
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Single-Value Mode
Output Group Box
Measure Value in Ohms
The actual measured resistance in ohms is displayed after a test. The deviation from the ideal value is displayed after a test.
Deviation
Output Group Box
Figure 6-4: Output Group Box with Pass Drop-Down Selections
Pass
Click the drop-down arrow at the right of the box and select either: Tape and Reel (Test result: 1)All passed devices are sent to the taper. Bucket 7 (Test Result: 8)All passed devices are sent to bucket 7 (sort 8), which is labeled GOOD 1.
Reject
All failed devices are sent to bucket 2 (sort 3), which is labeled REJECT. This is hard-coded into the software and cannot be changed by the user. All devices with open resistance are sent to bucket 1 (sort 2), which is labeled OPEN. This is hard-coded into the software and cannot be changed by the user.
Open
Status Group Box

Passed The cumulative count of all passed devices is displayed incrementally. The cumulative count of all devices failed because of test results outside the resistance tolerance is displayed incrementally. The cumulative count of all devices with open resistance is displayed incrementally.
Rejected
Open
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Other Features
Start Test Delay Type the delay in milliseconds after the handler gives the start test command and before it reads the test results from the Keithley meter. Check this box to save all test results to a log file. Uncheck this box to not produce a log file. Test results are displayed for each test, with the measured resistance in ohms first, followed by the sort, followed by the deviation.
Save to Text File
Readings
Example Test Result

An example of a good reading or test result shown in the Readings box might be: 99944.90000, 1, -0.0551000 This devices resistance is 99944.9 ohms, its sort or test result is 1, and its deviation is -0.0551. The test has followed the formula: Deviation (in %) = (Measured Value - Ideal Value) / (Ideal Value) x 100. Working this out, we see:
Measured Value Ideal/Nominal Value Measured Value minus Ideal Value divided by Ideal Value times 100 Deviation in percentage 99944.9 100000 -55.1 -0.00055 100 -0.0551
Because the percentage of deviation is within the tolerance range, the device is passed, and the test result 1 is sent to the handler.
Buttons
Display Bin Result Click this button to display a list of the correlations between sorts (test results) and bins (physical destinations) (Figure 65). Click this button to start the Auto Run mode. You must click this Auto Run button before clicking the RUN button on the handlers Auto Run window. The tester waits for communication with the handler, and then tests all devices. Click this button to test a device that is currently in the tester socket.
Auto Run
Manual Test
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Single-Value Mode
Buttons
Stop Exit
Click this button to stop the Auto Run mode. Click this button to exit this test mode and return to the main window. Click this button to save any setting changes you have made. Click this button to clear all text from the Readings box.
Save Parameters Clear Readings
Figure 6-5: Binning of Each Test Result Displayed
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Multiple-Value Mode
The window for Multiple-Value mode is accessed from the Test Multiple Values Mode button on the main window.
Figure 6-6: Testing Multiple Values Window
Batch Group Boxes

Five identical Batch group boxes are on this window. Each is to be set up to one of the five device parameters. If a tested device is within the parameters of any one of these group boxes, it is sorted accordingly and sent to the specified destination for all devices with that set of tested parameters.
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Multiple-Value Mode
Totals Group Box
Figure 6-7: Batch Group Box (Left); Pass Output Bin Selections Drop-Down (Right)
Production Number Nominal Value in Ohms Tolerance (in %) Total Passed
Type the production number for this run. Type the nominal or ideal electrical resistance in ohms. Type the tolerance limit in percentage. The total number of devices passed that meet this set of parameters is displayed incrementally.
Totals Group Box
Figure 6-8: Totals Group Box
Reject
All failed devices are sent to bucket 2 (sort 3), which is labeled REJECT. This is hard-coded into the software and cannot be changed by the user. All devices with open resistance are sent to bucket 1 (sort 2), which is labeled OPEN. This is hard-coded into the software and cannot be changed by the user.
Open
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Total Rejected Total Open Total All Passes
The total number of failed devices is displayed here. The total number of open devices is displayed here. The total number of passed devices for all five sets of parameters is displayed here.
Other Features
Start Test Delay Type the delay in milliseconds after the handler gives the start test command and before it reads the test results from the Keithley meter. Test results are displayed for each test, with the measured resistance in ohms first, followed by the sort, followed by the deviation. See "Example Test Result" on page 6-6 for an example. Check this box to save all test results to a log file. Uncheck this box to not produce a log file. Click this button to display a list of the correlations between sorts (test results) and bins (physical destinations) (see Figure 6-5 on page 6-7). Click this button to start the Auto Run mode. You must click this Auto Testing button before clicking the RUN button on the handlers Auto Run window. The tester waits for communication with the handler, and then tests all devices. Click this button to test a device that is currently in the tester socket. Click this button to stop the Auto Run mode. Click this button to exit this test mode and return to the main window. Click this button to save any setting changes you have made. Click this button to clear all text from the Readings box.
Readings
Save to Text File
Display Bin Result
Auto Testing
Manual Testing
Stop Exit
Save Parameters Clear Readings
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Document Overview
This document discusses the following main topics: Topic Operation Overview Vibrator Controls Air Jets and Sensors Bowl Feeder Changeover Procedure Emptying the Bowl Feeder of Devices Removing Bowl Feeder Changeover Parts Installing Bowl Feeder Changeover Parts Troubleshooting Principles Page 7-1 7-2 7-5 7-7 7-8 7-11 7-13 7-16
Operation Overview
The operator pours devices into the center bowl, and turns on the vibrators. Devices move in the circular track from the bowl to the tooling area; are straightened or blown off the track at the first two sensors, and move through the inline (final output track) to their next destination. Dead nest Inline track On/off sensor (#3) Discharge
Comeout
Tracks in bowl Tooling area (circular track from comeout to discharge)
Sensor 2 at air jet 4 Sensor 1 at air jet 2
Figure 7-1: Bowl Feeder Viewed from Above
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Vibrator Controls
The bowl feeder has two vibratory systems. The vibrator controlling the inline vibrates constantly. The vibrator controlling the bowl feeder itself vibrates intermittently, when it is necessary to refill the inline. Adjusting the control to a higher number increases the vibratory speed, or amplitude. In some cases, each of these two vibratory systems has its own control box; in other cases, they are combined in one dual-control box with two adjustment dials and on/off switches.
Vibrator with Manual Controls

Manual control boxes, as shown in Figure 7-2 and Figure 7-3, have only an off/on switch and a dial to adjust the vibratory speed, or amplitude.
Figure 7-2: Rodix Feeder Cube Dual-Control Box
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Operation Overview
Vibrator Controls
Figure 7-3: Rodix Feeder Cube Single-Control BoxTwo Versions
Vibrator with Programmable Controls

A vibrator with programmable controls has a digital display and buttons to enter the menu and adjust the settings.
Figure 7-4: Rodix Feeder Cube with Digital Display
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Figure 7-5: Both types of Feeder Cubes Used Together
The following is just a brief guide to the controls. See the manufacturers documentation for a fuller explanation.
Table 1: Control Keys

Key
I/O ENTER BACK [Up arrow] [Down arrow]
Function
Controls run, stop, and override Accesses menu (when held down); inside menu, selects menu item Moves back to higher level menu; back to normal operating display Increases a setting; steps up through program menu Decreases a setting; steps down through program menu
Table 2: Display
Display Area
Left side Left side Left side Right side Right side Right side Right side
Display
[message] A F R S O A
Reference
Status line message Amplitude power setting Vibrating or resonant frequency Run input Sensor input Output to vibratory feeder Auxiliary output
Meaning
(see Table 3) Percent of maximum Measured in hertz 1 = on/closed; 0 = off/open 1 = on/closed; 0 = off/open 1 = on; 0 = off 1 = on; 0 = off
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Operation Overview
Air Jets and Sensors
Table 3: Status Line Messages

Message
Stop/Run Override Run Input Parts Sens Empty/Jam Analog Low Zero Speed Run Run/CFR
Meaning
The I/O button has been pressed to disable control operation. The I/O button has been pressed and held so the control will feed without interruption from Sensor or Run inputs. The run jumper has not been made. The parts sensor logic is telling the control to stay off. Empty bowl timer has timed out because devices did not pass the sensor to reset the timer. Press the I/O key. An external signal is in control of the speed input. Sow speed used when 2 speed has been selected and the sensor is not made. The output is off because the output is set to 0.0%. The feeder is running normally. Constant Feed Rate sensor is regulating the feed rate.

Four air jets on the bowl ensure the devices are delivered to the inline with the correct orientation. Two sensors accompany the air jets. S1 is at air jets 1 and 2; S2 is at air jet 4.
Figure 7-6: Air Jets 1 and 2 with Sensor (Left); Air Jets 3 and 4 with Sensor (Right)
Air jets 1 and 2 increase the feed rate. Air jet 3 blows off stacked or standing-up devices, and air jet 4 is the blow-off for the final selector.
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The air jets work with the sensors in guiding the devices. The force of each air jet can be adjusted at the air flow controlssmall screws that can be turned and locked in position.
Figure 7-7: Air Tubes with Air Flow Controls and Sensor Controllers (Left); Air Flow Control Close-up (Right)
The inline bowl sensor detects when the line of devices in the inline track no longer block the sensor, and the main bowl vibrator turns on and delivers more devices to the inline track.
Figure 7-8: Bowl Sensor at Inline Track
Notice in Figure 7-8 that the line of devices ends just at the pathway between sensor halves. When the next device is taken, the sensor will be unblocked, causing the bowl feeder to vibrate more devices into the inline track.
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Bowl Feeder Changeover Procedure

If your bowl feeder will be processing more than one device type or size, you may have obtained extra parts for the bowl feeder that you can change, specific for each device size. Each set of exchangeable parts is called a changeover kit. CAUTION: Before starting the bowl feeder, make sure that all the parts of the changeover kit are the correct ones for the device you are going to process.
Figure 7-9: Various Sizes of Devices
Figure 7-10: Bowl Feeder Changeover Kit Tooling Fastened to Storage Plate
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The label for each changeover kit part is stamped on it. It shows the changeover kit part ID, and the device size that is to be used with the part. CAUTION: Store unused changeover kit parts on the storage plate (Figure 7-10). These parts are hand-machined to fit your unique bowl feeder, and are not easily replaced if lost.
Changeover Kit for Bowl Feeder

Device ID
1005 1505 1206 2010 2512
Device Size
.050 x .103 .050 x .150 .065 x .125 .100 x .205 .125 x .260
Discharge & Inline Track

1005E .050 x .0103 & .0150 1005E .050 x .0103 & .0150 1206E .065 x .125 2010E .100 x .208 2512K .125 x .206
Dead Nest
700-485 .050 x .100 700-490 .050 x .150 700-491 .065 x .125 700-492 .100 x .205 700-493 .125 x .260
Pickup Tip
CNT200-000 (round) CNT200-000 (round) CNT200-000 (round) CNT200-001 (square) CNT200-001 (square)
The changeover procedure for the bowl feeder can be broken down into separate tasks: Task Emptying the bowl and inline track of devices Removing changeover parts for one device size kit Installing changeover parts for new device size kit Page 7-8 7-11 7-13
CAUTION: Don't bump the inline sensors or the inline track. Bumping can throw them out of their exact position and require recalibration.
Emptying the Bowl Feeder of Devices

If desired, you can empty the bowl feeder of all devices before they run out naturally (this is called the quick-dump method). To empty the bowl feeder of all devices by the quick-dump method: 1. Hold devices back with a finger above the comeout site until all devices downstream of finger run out to the inline.
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Emptying the Bowl Feeder of Devices
Figure 7-11: Holding Devices Above Comeout
2. Shut the bowl vibrator off, but leaving the inline vibrator on. 3. When the inline is clear, shut off the inline vibrator. 4. Put a bucket snug against the comeout. 5. Loosen the 2 bolts on the comeout. Open the left side, and retighten the bolts so they don't vibrate.
Figure 7-12: Masking Tape Guiding Devices Out the Comeout
TIP: You may want to place a piece of masking tape across the track just below the comeout to guide devices out the comeout.
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Figure 7-13: Unscrewing and Opening Comeout
6. Turn the bowl vibrator back on (at a higher speed; a higher number) and let the devices run out the comeout.
Figure 7-14: Devices Falling from Comeout into Bucket
7. Close and retighten the comeout.
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Removing Bowl Feeder Changeover Parts
Removing Bowl Feeder Changeover Parts

To remove the parts of a changeover kit: 1. Unscrew the bolt on the dead nest stop and remove it.
Figure 7-15: Dead Nest Stop on Dead Nest (Left); Dead Nest with Stop Removed (Right)
2. Unscrew the other bolt and remove the dead nest.
Figure 7-16: Dead Nest Removed from Frame
3. Unscrew the 5 bolts on the inline track top confinement and remove it (Figure 717).
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Figure 7-17: Inline Track with Top Confinement (Left); with Top Confinement Removed (Right)
4. Unscrew the bolts on the discharge top confinement and remove it.
Figure 7-18: Discharge with Top Confinement (Left); with Top Confinement Removed (Right)
NOTE: After emptying the bowl feeder of parts and removing a changeover kit, wipe out all surfaces with a lint-free cloth and stainless steel cleaner. Keeping the feeder clean of particles and debris makes for smoother passage of devices and fewer jams. TIP: If devices are mixed with any foreign particles, you may want to put them in a kitchen strainer to remove small particles before pouring them into the bowl feeder.
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Installing Bowl Feeder Changeover Parts

To install a changeover kit: CAUTION: Tighten the screws only 'finger-tight'; do not overtighten. 1. Put on the discharge top confinement, fitting it over the dowel pins, and screw it down, using 2 short bolts (Figure 7-19).
Figure 7-19: Discharge Without Top Confinement (Left); With Top Confinement (Right)
2. Put the inline track top confinement (with the grooved side down and to the left) on the inline, fitting it over the dowel pins. You should be able to see the hole for the devices at the left side of the end (Figure 7-20).
Figure 7-20: Inline Track Top Confinementby Inline (Left), Fitted on Inline with Device Slot at Left (Right)
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3. , Screw down the inline top confinement. 4. Check the positioning by putting the alignment block at the end of the inline instead of the dead nest (Figure 7-21), so that the pickup nozzle fits into the harge hole.
Figure 7-21: Alignment Block
5. When the alignment is good, remove the alignment block and fasten it to the storage plate. 6. Put the dead nest at the end of the inline, fitting it over the dowel pins (Figure 722).
Figure 7-22: Dead Nest
7. Put the dead nest stop on top of the dead nest, with the stop pin lying in the
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track (Figure 7-23). 8. Screw the 2 long bolts in through the dead nest and dead nest stop (Figure 723).
Figure 7-23: Dead Nest and Dead Nest Stop
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Troubleshooting Principles
Time the movement of devices from one level of the circular track to the same place on the next level of the circular track (for example, at the comeout border). This is one full rotation. If a marked device makes one full rotation in 90 seconds, that is too fast. Turn down the main bowl feeder vibrator. If devices are coming out wrong side up, increase the air jets. If some devices are getting past sensor 2 wrong side up, it is because the main bowl feeder vibrator is turned up too high, causing too many parts to feed in a steady stream, where sensor #1 can't handle them all. Turn down the main bowl feeder vibrator. When processing smaller devices, turn down the air jets. You want just enough air to blow off a single misaligned device at sensor #1. If the air jet is too strong, it will blow down the properly aligned device next to it also, turning it over and making it misaligned. The dials on the control adjust the speed of vibration. A higher number on the dial causes a faster vibration speed, and faster device movement. The tiny screws on the air valves adjust the air jets. If you change device types frequently, you may not want to lock the air valves at a setting, but if you seldom change device types, then lock the air jet setting once it is adjusted correctly.
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Chapter Overview
This chapter is broken into discrete topics which may bear no relation to each other, but which are designed to assist the operator and/or technician to troubleshoot error conditions in the Exatron system. This chapter discusses the following maintenance tasks and their frequency: Task Backing Up the Computer Cleaning the Handler Cleaning or Replacing the Suction Cup Lubricating the Bearing Shafts Checking Lead Screw/Coupling Tightness Motor Replacement Master and Slave Cool Muscle Motors Setting Up a Cool Muscle Motor Controller Replacing a Cool Muscle Servo Motor Programming a Cool Muscle Motor Checking Motor Serial Cables Air Regulator Maintenance Checking Incoming Air from the House Supply Checking the Moisture/Dirt Trap in the Air Regulator Checking the Air Regulator Shutoff Valve Adjusting Air Pressure on the Regulator Adjusting Auxiliary Air Regulator Adjusting Air Valves Vacuum Generator Maintenance Troubleshooting Vacuum Assemblies Checking and Replacing a Vacuum Air Filter Adjusting Pickup Nozzle Blow-Off Cleaning Vacuum Assemblies Checking and Setting the Vacuum Generator Solenoid Maintenance Opening the Computer for Part Replacement Fiberoptic Photoelectric Sensor Guidelines Taper Maintenance Laser Servicing Networking Frequency Monthly Daily Weekly Monthly or quarterly Monthly As needed Before installing motor As needed After installing motor Monthly Weekly Weekly Monthly As needed As needed As needed As needed Monthly or quarterly As needed As needed As needed As needed As needed As needed As needed As specified by OEM As needed Page 8-2 8-3 8-3 8-3 8-5 8-5 8-5 8-7 8-12 8-15 8-17 8-18 8-18 8-18 8-21 8-22 8-22 8-23 8-25 8-27 8-28 8-29 8-32 8-36 8-44 8-44 8-48 8-49 8-50 8-50
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Task Internet Access Setting LAN Connections and Required IP Addresses Testing Network Communication with Peripherals Remote Handler Control with WebEx Replacing Exatron Program File with an Upgrade Troubleshooting This chapter also discusses the following problems: Topic Motors Move Very Slowly System Does Not Pick Up Devices Reliably
Frequency Always As needed As needed As needed As needed As needed
Page 8-50 8-50 8-56 8-59 8-61 8-64
Page 8-64 8-64
Preventive maintenance on the Model 7000-BPR is fairly simple. Following this schedule will help to assure your Model 7000-BPR handler will continue to perform properly. WARNING! Keep fingers, hair, and clothing away from any moving parts on the handler. Its motors are very powerful and can cause severe injury. WARNING! Always reset all motors before running the machine. Do not run it without homing the motors. WARNING! Never try to stop an action of the handler with your hands or any other device. To stop the handler, press the EMO (emergency stop) button or click Pause on the screen. CAUTION: Do not lubricate any lead screws! Lubricating the screws will void the warranty. CAUTION: Do not use any cleaners or solvents on any bearings or lead screws! CAUTION: Always power off the system before doing any maintenance.
Backing Up the Computer

As job files and other data are created or modified, you will need to back up the computer system as a precaution against hard drive failure. Appendix B explains how to back up the entire system. Alternatively, you can back up a few files to a CD or DVD. CAUTION: Back up the computers hard drive monthly or oftener to prevent loss of data.
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Cleaning the Handler
Cleaning the Handler

Include the following in a daily cleaning routine for longer trouble-free operation: Use a camel-hair brush to remove dust from any optics such as a laser lens. Wipe the lead screw and linear bearing slides with a clean, lint-free cloth. Vacuum any debris and dust from inside the cabinets. Vacuum any debris from the computer chassis.
Cleaning or Replacing the Suction Cup

The suction cup on each pickup head of the Model 7000-BPR is subject to fairly serious performance degradation with dirt and oil buildup. This buildup may be due to substances on the devices themselves, such as mold release agent, oils and soaps from anti-static containers, etc. Wipe the suction cup with a cotton swab dipped in isopropyl alcohol or other suitable (evaporative) cleaning agent. This is best performed when the system is switched off to avoid any motor movement during the cleaning process. Depending on volume of use, the suction cup may require replacement. A list of replacement part numbers can be found in Chapter 9.
Lubricating the Bearing Shafts

The bearings on the pickup pushers are lubricated at the factory. However, these bearings need relubrication at regular intervals. The lubrication interval will be different for each handler because this interval is dependent on several factors. These factors are: Operation hours Speed Load Temperature Stroke Environmental conditions
The two factors that will change from handler to handler are operating hours and environmental conditions. Exatron recommends that the bearing shafts be lubricated every month at a minimum. Exatron strongly recommends the lubrication be done weekly, especially if the handler is in extreme environmental conditions or is operated more than 80 hours per week. Use visual
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inspection to determine when lubrication will be required in these cases. You should see a thin, clean layer of grease on the stainless steel bearing guide shafts. If grease is not seen, or if they are dirty, the shafts should be cleaned and re-lubed. Manufacturer Kerk Thomson Thomson Product Lead screws Bearings Bearing shafts NONE NONE M1 (Starrett brand) Treatment Comment Black TFE coated screws are never lubed Bearings are Super 4, Super 8, and Super 8 OPN M1 is petroleum-based, removes moisture
To lubricate the bearing shafts: 1. Power down the entire system. CAUTION: Do not use water or any cleansers to clean the bearing shafts. This will cause rust damage to the bearings. Also, do not lubricate any of the leadscrews; lubricate only the bearing shafts. 2. Apply an appropriate type of grease to a soft, clean, dry lint-free cloth. Wipe the cloth along the bearing shaft, making sure no grease drops onto the lead screw. Be sure to remove all the old grease and debris. Exatron recommends a Teflon-based grease or M1. Exatron uses Linear Lube grease manufactured by Thomson. > The amount of grease used is difficult to specify. The goal is to attain a thin layer of grease along the entire length of the shaft. 3. On a linear motor track, apply a small dab of grease at one point. Then by hand move the Z-axis block along the entire length of the shaft several times. > If no film of grease is seen, apply another small dab of grease and repeat the process. > If there is any clumping of grease along the length of the shaft, remove the excess grease with a dry cloth. Once again move the Z axis block manually several times until a thin film is achieved.
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Checking Lead Screw/Coupling Tightness
Master and Slave Cool Muscle Motors
Checking Lead Screw/Coupling Tightness

Mechanical alignment of this system relies on the lead screws and motor coupling being tight. To tighten lead screws and motor coupling screws: 1. With the power to the system off, open the two hinged covers and manually push and pull on the lead screws. They should not be loose in their long axis (they will turn, but should not pull in and out at all). 2. Using a hex driver (preferably without ball tip), make sure the screws on the motor coupling are tight. The screws are accessible through the slots in the motor mounting bracket. Turn clockwise to tighten. The screws should be tight, but do not over-tighten, as it is possible to break the screws. 3. If the lead screws seem at all loose, it will be necessary to tighten them against the motor coupling. Tighten the lead screws only with the power off! Using a hex driver (preferably without ball tip) loosen the screw on the motor coupling, accessible through the slots in the motor mounting bracket. Loosen only the screw nearest the lead screw, not nearest the motor. 4. When that screw is loose, push on the lead screw, towards the coupling, to seat the lead screw tightly against the bearing mounted in the system wall. 5. With the lead screw tight against the coupling, tighten the coupling screw again.
Motor Replacement
When replacing a motor, several tasks may be involved. These are explained in the following sections. For a Cool Muscle motor, you may need to adjust the configuration before installing it; and after installation, you need to program the motor. Cool Muscle motors can be used as master or slave motors. You can program a replacement Cool Muscle motor through the Exatron software. See "Programming a Cool Muscle Motor" on page 8-15 for instructions.
Master and Slave Cool Muscle Motors

This section applies to Cool Muscle motors used as master and slaves. Several principles regarding master and slave motors need to be considered. A master motor is always powered through the terminal block on its network card (Figure 8-1, bottom; and Figure 8-2, left). A slave motor can be powered through either of two methods:
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> Through the terminal block on its network card (Figure 8-2, middle and right), or > Through an RS-232 cable attached to the input connector on its network card (Figure 8-1, top; and Figure 8-3, middle and right).
Input connector
Terminal block + = 24V -- = GND 3 & 4 unused

Figure 8-1: Terminal Block and Input Connector on Network Card
The following partial diagrams illustrate the differences.
Figure 8-2: Slave Boards Powered Through Terminals
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Motor Replacement
Setting Up a Cool Muscle Motor Controller
Figure 8-3: Slave Boards Powered Through RS-232 Cables
Notice that in both Figure 8-2 and Figure 8-3, the master board on the left (circled in blue) is powered through its terminal. In Figure 8-2, the slave boards (middle and right, circled in red) are likewise powered through their terminals, as shown by the red wires. In this case, only the sensors are powered through the RS-232 cables. However, in Figure 8-3, the slave boards (middle and right, circled in red) are powered through their RS-232 cables, since no terminal wires are present. In this case, both the slave boards and the sensors are powered through the RS-232 cables. A master motor uses a network card equipped with an interface card. The cards together are called a master set. A slave motor uses a network card without an interface card.

If you have ordered a master motor controller (a network card with interface card), it will look like the board at the right side of Figure 8-4. It has a small board (the interface card) piggybacked on top.
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Figure 8-4: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Network Card
Figure 8-5: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations
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Motor Replacement
If you are going to use the controller as a master, leave the JP3, JP4, and JP5 jumpers in the position shown at the right side of Figure 8-5. If you are going to use the controller as a slave, pull off the JP3, JP4, and JP5 jumpers and replace them in the position shown at the left side of Figure 8-5.
Master Network Card with Interface Card (See Figure 8-6)

Jumper
JP1 JP2 JP3 JP4 JP5
Pins Connected (Covered)

2 (open) 2 (open) 2&3 2&3 2&3
Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. Interface card is attached to network card. Interface card is attached to network card. Interface card is attached to network card.
Slave Network Card Powered Through Terminal Block (See Figure 8-7)
Jumper
JP1 JP2 JP3 JP4 JP5

2 (open) 2 (open) 1&2 1&2 1&2
Used When...
Power is supplied through terminal block on card. Power is supplied through terminal block on card. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.
Slave Network Card Powered Through RS-232 Cable (See Figure 8-8)
Jumper
JP1 JP2 JP3 JP4 JP5

1 & 2 (closed) 1 & 2 (closed) 1&2 1&2 1&2
Used When...
Power is supplied through RS-232 serial cable. Power is supplied through RS-232 serial cable. NO interface card is attached to network card. NO interface card is attached to network card. NO interface card is attached to network card.
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Interface Card Piggybacked on Master Network Card (See Figure 8-6, Left)
Jumper
JP1 JP2

1&2 2&3
Used When...
RS-232 is used rather than RS-485. RS-232 is used rather than RS-485.
JP5 - Pins 2 & 3 connected Interface Card: JP1 - Pins 1 & 2 connected
JP3 - Pins 2 & 3 connected
JP1 open
JP2 open
Figure 8-6: Master Network Card with Interface Card on Top
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Motor Replacement
JP1 open
JP2 open
Figure 8-7: Slave Network Card Powered Through Terminal Block
JP1 JP2 Pins 1 & 2 connected on both

Figure 8-8: Slave Network Card Powered Through RS-232 Cable
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Replacing a Cool Muscle Servo Motor

The instructions in this procedure apply to Cool Muscle motors. To replace a servo motor, use the instructions in this section. The new parts to be assembled and installed are shown in Figure 8-9. # 4 x 1/4" x 1/4" diameter nylon spacers # 4 split washers 4/40 x 2.125" # 4 x 9/16" x 1/4" diameter nylon spacers Motor drive board cover (PET-K66-A) # 4 nylon washers 4/40 x 1/4" Serial port/network card cover (PET-H39-C)
Motor drive board (inside cover) (MOT16-001)
Nema 17 Motor (MOT16-001)
Client network card (MOT16-020)
Short style motor communication cable (MOT16-033)
Figure 8-9: New Motor Assembly to Be Installed
To replace a servo motor: 1. Place the two nylon washers on the 4/40 x 1/4" screws, and place the screws into the holes of the motor drive board, as shown in Figure 8-10. 2. Place the motor drive board inside the cover with the two screw holes aligned (Figure 8-10).
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Motor Replacement
Figure 8-10: Screwing Motor Drive Board in Cover
3. Wrap the rubber grommet around the wires, and slide the grommet into the grommet holder, as shown in Figure 8-11. 4. Slide the #4 split washers onto the long screws, and slide the four screws through the serial port/network card cover (Figure 8-11). Slide the short (1/4"long) nylon spacers onto the screws.
Figure 8-11: Adding Grommet and Long Screws
5. Slide the client network card onto the long screws, with the connectors facing the cover holes, as shown in Figure 8-12. 6. Slide the long (9/16"-long) nylon spacers onto the screws (Figure 8-12).
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Figure 8-12: Sliding Network Card into Cover; Adding Long Spacers
7. Slide the motor driver board in its cover onto the long screws so the two covers are piggybacked, as shown in Figure 8-13. 8. Press the short style motor communication rainbow cable into the connectors of both boards (Figure 8-13).
Figure 8-13: Sliding Both Covers Together; Adding Rainbow Cable
9. Attach the assembly to the handler.
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Programming a Cool Muscle Motor
Programming a Cool Muscle Motor

After you have replaced an old Cool Muscle motor with a new one, you need to program its parameters (sometimes called initializing the motor). The Exatron software streamlines this process for you. To program a new Cool Muscle servo motor: 1. Open the Exatron software. 2. On the Main window, click the Function menu, and click Initialize Motors.
Figure 8-14: Initialize Motors Menu Item
3. In the Initialize Motors dialog box, click the drop-down arrow to the right of the Select Motor box, and click the motor you want to initialize (Figure 8-15). 4. Click Initialize Motor. 5. Click Exit.
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Figure 8-15: Initialize Motors Dialog Box
For more information, see the motor manufacturers manual.
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Checking Motor Serial Cables
Checking Motor Serial Cables

The motors on the Model 7000-BPR are attached to the system via short serial cables. Check that these cables are plugged in tightly to the CPU box, and the DB-9 connectors are securely screwed to the motors themselves.
Figure 8-16: Serial Cables
If your handler has a large number of motors, it may have a serial or network hub to add serial COM ports. Make sure all these connectors are secure, also.
Figure 8-17: Serial Hub
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Air Regulator Maintenance

Most Exatron handlers use compressed air, which also requires an air regulator. A high quality air regulator with coalescing air filter and shutoff valve is supplied on your handler. It supplies air at the pressure you specify for the whole handler. Some handlers may also have a digital sensor, which shuts down the handler if the incoming air pressure drops below the limit you set on the digital sensor. CAUTION: NEVER operate any Exatron equipment which requires compressed air without an approved air regulator and shutoff valve. The external air regulator assembly includes one or two oil/water particulate traps which should be visually inspected on occasion. This regulator should be set at factory air pressure of 80 PSI. The system requires a minimum of 80 PSI to operate properlyspecifically, to generate sufficient vacuum through the venturi to pick up devices from the trays. The incoming air line exits the regulator and splits to supply the vacuum generator and the internal air regulator/test site manifold.
Checking Incoming Air from the House Supply

The first step in ensuring a trouble-free air supply is to ensure the incoming air is adequate. Make sure the incoming air supply is at least 3 CFMs (cubic feet per minute). Make sure the needle on the handlers air regulator is not spiking or pulsing. If it is, the house air supply is inadequate.
Checking the Moisture/Dirt Trap in the Air Regulator

Check the moisture/dirt trap on the air regulator and the coalescing filter chamber. Verify that they are clean, empty and dry. There should be no oil and no water in any chamber. If they are dirty, physically disconnect the incoming air pressure supply from the air regulator and clean the trap and filter as needed. Excessive moisture and/or particulate buildup in the filter traps suggests the air supply to the system is too wet and/or dirty. CAUTION: Excessive moisture in the system can damage the vacuum generator and air valves.
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Checking the Moisture/Dirt Trap in the Air Regulator
Figure 8-18: SMC Air Regulator
Follow this procedure for your SMC brand air regulator. To check or replace the air filter: 1. Unscrew the small black screw at the bottom of the filter chamber and remove. If water is present, there is water in the air lines and you have a problem that you must correct.
Figure 8-19: Small Black Screw Removed
2. Unscrew the metal casing.
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Figure 8-20: Metal Casing Unscrewed
3. Snap off the clear glass casing.
Figure 8-21: Clear Glass Casing Snapped Off
4. Unscrew the black inner screw that has edges like propeller blades.
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Checking the Air Regulator Shutoff Valve
Figure 8-22: Large Black Inner Screw Removed
5. Remove the white filter and clean or replace if necessary, and reassemble in reverse order. If you find it necessary to clean the trap and/or filter more often than once a month, you should correct the problem at your in-house air compressor. Check your manufacturers manual for the exact procedure necessary.
Checking the Air Regulator Shutoff Valve

Check the operation of the shutoff valve once a month. To check the operation of the shutoff valve: 1. Turn the Off/On switch off and verify that the air is indeed off. Turn the switch back on. 2. Check the PSI setting. > Some special-case changeover kits may require less than 80 PSI. However, in general, set the air regulator to 80 PSI. If the air regulator is turned off, turn it on by turning the Off/On switch one quarter-turn counterclockwise. You can leave the air regulator turned on except when you are checking its operation.
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Adjustment knob On/off switch in OFF position On/off switch in ON position
Figure 8-23: SMC Air Regulator Turned Off (Left), On (Right)
Adjusting Air Pressure on the Regulator

You can increase air pressure at the air regulator. To adjust the air pressure: 1. Pull up on the black adjustment knob above the display, and turn it. > Turn it clockwise to increase the pressure. > Turn it counterclockwise to decrease the pressure. 2. Push the knob back down to lock it when you have finished the adjustment. If your handler has an auxiliary or internal (pusher) air regulator, see the next subsection.
Adjusting Auxiliary Air Regulator

The auxiliary or internal air regulator (or auxiliary pusher regulator; Figure 8-24) "steps down" the air pressure for use by the test site air cylinders on those systems using them. The air cylinders found on most test sites require only 30 to 50 PSI to operate properly, and over-driving
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Adjusting Air Valves
the cylinders can shorten the life expectancy of both the cylinders and the test sockets. Some sockets require more force than others to operate. The air pressure exerted on the sockets should be adjusted to be just enough for the particular sockets in use. Pull out the black adjustment valve and turn it to step down the pressure here to 30-50 PSI.
Adjustment valve
Figure 8-24: Auxiliary Air Regulator

Pressurized air for the air cylinders at the test sites (and thermal heads, if so equipped) is controlled by a series of 24-volt DC air valves mounted on a manifold block. Each air valve is wired through an override button which will turn the valve on while it is pressed. However, the override button will not turn off a valve which has been actuated by the handler itself.
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Lock nut
Air flow control adjustment knob

Figure 8-25: Air Valves with Control Adjustment
To adjust the air flow at the air valve: 1. Turn the lock nut counterclockwise to unlock the adjustment knob. 2. Turn the air flow control adjustment knob: > Turn the knob clockwise to lessen the air flow, or... > Turn the knob counterclockwise to increase air flow. 3. When air flow is appropriate, turn the lock nut clockwise to tighten it.
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Vacuum Generator Maintenance

Exatron uses one of three types of SMC brand vacuum assemblies on the handlers, depending on the handler setup.
Type Exatron part number SMC part number Port configuration Vacuum supply valve Solenoid valves Interface plates Blow-off screw location Number of air tubes Usage Handler model
K15 Vacuum Generator

PNE022-100 NZX1102-K15LZ-D23CL 1 (PV<-->PS<-->PD) a Normally closed (NC) Short (Figure 8-27, top) 1 (Figure 8-28) PS port (Figure 8-29, left) 1 (Figure 8-26) Has built-in venturi Used by most Model 900s
K35 Vacuum Generator

PNE022-007 NZX1102-K35LZ-D23CL 3 (PV<-->PS<-->PD) b Normally open (NO) Long (Figure 8-27, bottom) 2 stacked (Figure 8-28) PS port (Figure 8-29, left) 1 (Figure 8-26) Has built-in venturi Used by many Model 8000s
K35 Vacuum Switch

PNE022-023 NZX100-K35LZ-D21CL 3 (PV) (PS<-->PD) c Normally open (NO) Long (Figure 8-27, bottom) 2 stacked (Figure 8-28) PD port (Figure 8-29, right) 2 Uses vacuum pump Used for large number of pickup nozzles or complex air pressure needs
a. The PV, PS, and PD ports are all common to one another. b. The PV, PS, and PD ports are all common to one another. c. The PS and PD ports are common to each other.
PD port PS port
PV port
Figure 8-26: K15 Vacuum Generator
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PD (upper hole, Figure 8-26) is the air supply port for the release valve. PS (middle hole, Figure 8-26) is the air supply port for the vacuum valve. PV (lower hole, Figure 8-26) is the vacuum supply port.
Figure 8-27: Vacuum AssembliesK15 (Top); K35 Switch for Vacuum Pump (Bottom)
The black solenoid valves for K35 are longer than those for K15 (Figure 8-27). Also, K35 has two interface plates, whereas K15 has only one.
Figure 8-28: Extra Holes in K15 Interface Plate
The locations of the holes in the interface plates (Figure 8-28) serve to redirect the internal air flow. Vacuum switches require the use of a separate vacuum pump.
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Troubleshooting Vacuum Assemblies
PD portBlow-off adjustment screw location when vacuum pump is used
PS portBlow-off adjustment screw location when in-house air is used
Figure 8-29: Blow-Off Adjustment Screw Locationon Vacuum Generator (Left); on Vacuum Switch (Right)
Troubleshooting Vacuum Assemblies

Air Regulator
Keep the air regulator set to 80 PSI. If the needle on the air regulator varies more than 10 lbs, there is not enough air flow, although there may be enough air pressure. The reduced air flow will confuse the software and cause improper handling because not enough air is being supplied. If ithe air regulator is set a little higher, it harmlessly bleeds the excess air. However, it should not go above 90 or 100 PSI. If the air regulator drops drastically, perhaps by 40 lbs. or more, not enough air is being supplied, and the source of the problem is somewhere outside the handler. Check your in-house air supply. Are too many machines being supplied by one compressor? Is the compressor dirty or wet? If the problem develops gradually, it may be caused by water in the line. If the problem does not appear at startup but only after the handler has run awhile, again it may be caused by water in the line. If water gets into the vacuum generator or switch, it causes plugging so it loses vacuum and wont pick up devices. This can be due to improper air compressor maintenance.
Vacuum Generators
When the air regulator shows enough pressure but the vacuum at the pickup nozzle is too low, the origin of the problem is somewhere between the air regulator and the vacuum generator. If a problem appears consistently, even at startup, it may be dirt in the air filter. Check for: Dirty air filter in the vacuum generator Loose or pinched air hose Loose air fitting
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Vacuum Switches Used with Vacuum Pump

When using a vacuum switch with a vacuum pump, the danger is in turning the air pressure too high. The maximum air pressure coming from the vacuum pump must be no higher than 50 PSI. Any greater air pressure may damage components and will void the Exatron warranty. CAUTION: When using a vacuum pump, set the maximum air pressure no higher than 50 PSI to avoid damage.
Checking and Replacing a Vacuum Air Filter

Whether your handler uses a vacuum generator or a vacuum switch, it has a built-in replaceable air filter (#PNE022-020). The see-through plastic housing for this filter can be removed by hand. Replace the filter when it becomes visibly dirty, gray, or has obvious particulate matter buildup. If particle buildup is evident, the air supply lines should be checked for contaminants. Also, the moisture/dirt trap on the incoming air regulator should be checked. See "Checking the Moisture/Dirt Trap in the Air Regulator" on page 8-18 for instructions. Inspect the vacuum generators air filter weekly. The filter should be clean and white. CAUTION: A dirty filter means poor handler operation. Replace your filter!
Figure 8-30: Dirty Filter (Left) Versus Clean Filter (Right)
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Adjusting Pickup Nozzle Blow-Off

The procedure in this section allows you to adjust the blow-off strength for each pickup nozzle individually. You can adjust the blow-off for each individual pickup nozzle at the vacuum generators. There is one vacuum generator for each nozzle. You adjust one screw on each vacuum generator or switch, but the screw location differs according to whether: Your handler has a vacuum generator and is attached to an in-house air supply, or Your handler has a vacuum switch and is attached to its own vacuum pump (perhaps because of having many pickup nozzles). See the locations compared in Figure 8-29.
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Adjusting Blow-Off for Handler Using In-House Air Supply

If the handler uses an in-house air supply, the vacuum/blow-off is connected to the PV port (the lowest hole, Figure 8-31) and you can adjust the screw in the PS port. Turning it one complete revolution often makes an adequate adjustment. CAUTION: Do not over-adjust the blow-off adjustment screw. If the screw is turned too much, it will come out and make the blow-off inoperable. To increase the blow-off, turn the screw counterclockwise to loosen the screw. To decrease the blow-off, turn the screw clockwise to tighten the screw.
PS portBlow-off adjustment screw when in-house air is used
PV portconnection for air supply or vacuum pump

Figure 8-31: Blow-Off Adjustment Screw at PS Port When Using In-House Air
Adjusting Blow-Off for Handler Using Vacuum Pump Air Supply

Compare the following locations with Figure 8-32. If the handler has its own vacuum pump and chamber(s) as shown in Figure 8-33 and Figure 8-34, the vacuum pump is connected to the PV port (the lowest hole, with the black tube). Therefore, the usual blow-off adjustment screw is removed and the blow-off fitting is attached to the PS port (the yellow tube), where the blow-off adjustment screw would have been. In that case, you must adjust the upper setscrew at the PD port (just above the yellow blow-off tube) instead. Do not turn it more than only one-eighth to one-fourth of a revolution. CAUTION: Do not over-adjust the blow-off adjustment screw. If the screw is turned too much, it will come out and make the blow-off inoperable. When using a vacuum switch with vacuum pump, 1/8" to 1/4" should be the maximum adjustment. To increase the blow-off, turn the screw counterclockwise to loosen the screw. To decrease the blow-off, turn the screw clockwise to tighten the screw.
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PD port
PS port
PV port
Figure 8-32: Blow-Off Adjustment Screw at PD Port When Using Vacuum Pump
Figure 8-33: Various Styles of Vacuum Pumps
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Figure 8-34: Vacuum Chamber
Cleaning Vacuum Assemblies

This section shows a quick way of cleaning a vacuum assembly. WARNING! Always wear safety glasses before cleaning a vacuum assembly. To clean a vacuum assembly: 1. Turn off the air supply, and turn off the air regulator to release air pressure. 2. Unscrew and remove the two screws from each of the two solenoid valves on each vacuum assembly (Figure 8-35).
Figure 8-35: Vacuum Assembly with Four Screws Highlighted
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3. Remove the two solenoid valves (Figure 8-37).
Figure 8-36: Vacuum Assembly with One Solenoid Valve Removed
Figure 8-37: Vacuum Assembly with Both Solenoid Valves Removed
4. Remove the gaskets from both solenoid valves (Figure 8-38). Be careful not to cut or damage the gaskets.
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Figure 8-38: Removing Gasket from Vacuum Assembly
Figure 8-39: Vacuum Assembly with Gasket Still Attached
> Occasionally a gasket may get stuck to the venturi when the solenoid valve is removed (Figure 8-39). Remove the gasket and save it.
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Figure 8-40: Vacuum Assembly with Both Solenoid Valves and Gasket Removed
5. Turn the air supply on and let it blow out the venturi. 6. Use a hand-held air supply to blow out each solenoid valve by hand. 7. Ater all parts are cleaned out, turn the air supply off before reassembling. 8. Press the gaskets back into the solenoid valves. 9. Replace the solenoid valves on the venturi and screw them in.
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Checking and Setting the Vacuum Generator

The vacuum generator is fitted with an electronic sensor that measures the strength of the vacuum drawn through the air lines. The sensor displays the result on the small LCD screen of the vacuum generator. When the vacuum is engaged, the display should give a reading for the level of vacuum in the system. (The kPa or mPa value is a percentage of the PSI.) The sensor puts out a signal when a given level of vacuum is reached, indicating the vacuum has a secure hold on the device being lifted. To check the vacuum generator adjustment: 1. Turn on the vacuum using the handlers vacuum override button, but do not attach a device to the nozzle or block it. 2. Cover the vacuum hole in the pickup nozzles suction cup with a device. > You will hear a noticeable change in the sound of the vacuum as it intercepts the device, and the green indicator LED should turn on. If the valves in the vacuum generator assembly become plugged with dirt, you may send the assembly back to Exatron Customer Service where it will be repaired, if possible, for a fee. Damage caused by a dirty air supply is not covered by the Exatron warranty. If you are experiencing dirt-clogged vacuum generator valves, check the air regulator. Verify that it is clean and properly installed. See "Air Regulator Maintenance" on page 8-18. Contact the Exatron factory for assistance as needed. The vacuum generator setting is more or less permanent. It should rarely, if ever, need to be recalibrated. The handler has one vacuum generator for each pickup head.
Figure 8-41: Vacuum Generator Controls
When the P1 value is reached, the signal is turned on. From this value and above, the handler considers that a device is attached to the pickup nozzle. When the P2 value is reached, the signal is turned off. For Exatron handlers, the P2 maximum value is set to 101 so that it will never be reached.
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As a general principle, a larger hole in the suction cup of the pickup nozzle will show a lower baseline value (when no device is attached) because the air flow is not obstructed as much as it is with a smaller suction cup hole (Figure 8-42). When the suction cup hole is smaller, the baseline pressure is higher (Figure 8-43).
Figure 8-42: Vacuum Generator Optimal Pressurefor Nozzle with Larger Hole
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Figure 8-43: Vacuum Generator Optimal Pressurefor Nozzle with Smaller Hole
If you replace a vacuum generator with a new one, you need to calibrate its settings. A new vacuum generator has both P1 and P2 set at zero, and EC set at 3. You will need to change these settings. The modes cycle through P1, P2, P3, (P4 is added for a vacuum switch using a vacuum pump system), and EC with repeated pressing of the SET button. Mode
P1 P2 P3 P4 EC Low limit High limit For other sensor For switch using a vacuum pump system Error code
Meaning
Desired Setting
8-10 points higher than vacuum on w/ no device present; minimum 60 101 61 or lowest n/a 0
Result
Device is considered as attached to pickup; green light on No device is considered as attached to pickup; green light off Not used Not used Not used
You can use either the vacuum override buttons on the handler, or the tiny vacuum override button on the vacuum generator itself (Figure 8-45).
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Vacuum button
Blow-off button
Figure 8-44: Vacuum and Blow-Off Override Buttons on Vacuum Generator
To calibrate the vacuum generator: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with no device attached to the nozzle and note the setting. This is the baseline value (Figure 8-45).
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Figure 8-45: P1 Baseline Value Example
4. Press the SET button to enter the programming modes. > P1 with the value is displayed. P1 sets the minimum limit at which the sensor detects a device. 5. Press one of the green arrow-shaped buttons to set the number at least 8 to 10 points higher than the baseline value (with no device attached), but no lower than 60 (Figure 8-46). The minimum should be 60. > Press the up-arrow button to increase the number displayed. > Press the down-arrow button to decrease the number displayed. > Factors such as weight of the device or rotation of the pickup nozzle may affect the number that works best for your handler.
Figure 8-46: P1 Set at Least 8-10 Points Higher Than Baseline
6. Press the SET button to advance to the P2 setting.
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> P2 with the value is displayed. P2 sets the maximum limit beyond which the sensor no longer detects a device. 7. Press the up-arrow button repeatedly to set the P2 number at 101, the maximum limit (Figure 8-47).
Figure 8-47: P2 Set to 101
8. Press the SET button to advance to the unused P3 setting. 9. Press the down-arrow button repeatedly to set the P2 number at 61 or the minimum limit. 10. Press the SET button to advance to the EC setting. > EC with the value is displayed. 11. Press the down-arrow button repeatedly to set the EC number at 0 (Figure 848). 12. Press the SET button again to return to normal operation mode.
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Figure 8-48: Error Code Set to Zero
Now you can check the settings. To check vacuum generator settings: 1. Power on with no air. > A 1 or 0 should be displayed on the LCD screen. The green light on the vacuum generator stays on. 2. Turn on the air and the vacuum, using the software. Do not attach a device yet. 3. Press the vacuum override button with NO device attached to the nozzle and note the setting. > The setting with no device attached should be at least 8 points lower than the P1 setting. 4. Now attach a device to the nozzle and press the vacuum override button. Note this setting number. > The setting with a device attached should be at least 68-75 or higher, or at least 5 points higher than the P1 setting. Lower numbers may indicate some problem with the air line, perhaps the tubes or compressor. 5. Finally, to test your settings, put a device on the nozzle and press the override button. With a device attached, a green indicator light is displayed on the vacuum generator (Figure 8-49). With no device attached, the light goes off (when EC is set to 0; if EC were set to 3, the indicator light would be red when no device is attached).
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Figure 8-49: Green Indicator Light with High Number Showing Device Attached
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Solenoid Maintenance
CAUTION: NEVER use oil or lubricant of any kind on solenoids. Keep the solenoids as clean as possible. If the handler is used with devices which have excessive mold flash, the solenoids will require cleaning regularly. The frequency is dependent upon how much mold flash gets into the solenoids. When cleaning solenoids, take care not to put excessive stress on solenoid wiring. Check all wiring for signs of wear, exposed conditions, or broken connections. Replace as needed with identical type of wire: standard or flex, same gauge, insulation, color, etc. When cleaning solenoids, check the plungers to be sure there are no burrs of any kind on their shafts. Solenoid life is proportional to the handler environment and how often the solenoids are cleaned. We recommend that all solenoids be replaced every two million cycles as part of a good preventive maintenance program. Replace any bent or damaged solenoid return springs with new parts from the Exatron factory. Refer to the hardware specifications in Chapter 9 for the part numbers of all solenoids and springs in your handler.
Opening the Computer for Part Replacement

The computer inside the Model 7000-BPR cabinet slides out on rails, making it easier to change any part of the computer (Figure 8-50).
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Figure 8-50: Computer Sliding Out of Cabinet on Rails
To replace a computer part on a cabinet-based model: 1. Unscrew and remove the 4 allen screws that bolt the computer to the computer base (Figure 8-51).
Figure 8-51: Four Computer Base Bolts
2. Pull the computer out by the top rim (Figure 8-52).
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Figure 8-52: Sliding Computer Out of Cabinet
3. Unscrew and remove the 2 bolts at the top front of the computer that secure the lid (Figure 8-53).
Figure 8-53: Front Bolts Securing Lid
4. Unscrew and remove the 6 bolts along the top edges of the computer (3 on each side; Figure 8-54).
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Figure 8-54: Top Bolts Securing Lid
5. Lift off the lid. 6. Replace any part that needs to be replaced. 7. Reassemble the computer in reverse order.
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Fiberoptic Photoelectric Sensor Guidelines

Each sensor on your handler is connected to a sensor controller, which displays whether the sensor is "seeing" any object. Most fiberoptic sensor controllers are set to L-ON (light on) by Exatron. This causes the output transistor to turn on when light is received by the sensor.
Figure 8-55: Omron Sensor Controller Set to L-ON
Figure 8-56: Green and Red Indicator Lights
The green light is the Stable Operation Indicator. When the sensor is operating normally under stable conditions, the green light should be ON. The red light is the Light Reception Indicator. When the sensor is receiving light, the red light should be ON.
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Taper Maintenance
Figure 8-57: Conditions of Indicator Lights
For both types of sensor (through-beam and reflective), the red light on means nothing is there; nothing is blocking or reflecting the sensor beam. If the red light is off, something is there, interfering with the sensor beam.
Taper Maintenance
If your handler uses a tape and reel, you need to keep the seal head clean. If you use a heat seal head, clean it with a cotton swab dipped in acetone, isopropyl alcohol, or other suitable (evaporative) cleaning agent. Be sure to do this when the seal head is cold. If you use a pressure-sensitive seal, replace the rubber pressure roller wheels when they get worn. Clean the sensor optics of dust with a very low blast of air.
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Laser Servicing
If the handler is equipped with a laser, see the manufacturers manual for service instructions. WARNING! Only a qualified in-house laser safety officer (LSO) should service the laser.
Networking
The next few subsections discuss ways of troubleshooting over a network.
Internet Access
It is strongly recommended that your handler be equipped with Internet access, without which Exatron cannot help you troubleshoot the handler remotely.
Setting LAN Connections and Required IP Addresses

The handler and its peripherals are on its own private network. To ensure communication between the Exatron software and peripheral devices such as the inspection camera, the IP addresses are static, set to the handlers own private network. Keeping the IP addresses as they come from the factory enables the handler software to communicate with the peripherals. CAUTION: Do not change any IP address associated with the handler or its peripherals unless specifically approved by Exatron. Changing IP addresses can make service billable even when the handler is under warranty. Because Exatron has optimized communication on this private network, performance cannot be guaranteed if additional devices are connected or additional non-Exatron software is installed. In order to connect the handler to a LAN for the purpose of remote servicing, Exatron requires the use of a network interface adapter. Exatron can supply a USB-to-Ethernet adapter as an option. Use this adapter to connect to the LAN; do not attach the handlers private network to the LAN. See the following chart for required IP addresses.
Required IP Addresses
IP Address
192.168.12.1 192.168.12.11 through 192.168.12.29 192.168.12.3 192.168.12.4 192.168.12.41 192.168.12.42 192.168.12.5
Component or Peripheral
Exatron PC Handler motors, sensors, PLCs Laser PC Camera/machine vision PC Camera 1 Camera 2 Peregrine tester
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Networking
Required IP Addresses
IP Address
192.168.12.51 through 192.168.12.59
Component or Peripheral
Other testers
A computer may have more than one LAN (local area connection) setup. In this example, LAN 3 is used. To set the LAN connection: 1. Double-click the icon in the lower left corner of Windows desktop to open a LAN connection setup (Figure 8-58).
Figure 8-58: LAN Setup Icon
> The Local Area Connection Status dialog box is displayed (Figure 8-59).
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Figure 8-59: Local Area Connection Status Dialog BoxGeneral Tab
2. Set the parameters on each tab as shown in the following figures.
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Networking
Figure 8-60: Local Area Connection Properties Dialog BoxGeneral Tab
3. Under the General tab of the Local Area Connection Status dialog box, click the Properties button (Figure 8-60). > The Local Area Connection Properties dialog box is displayed.
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Figure 8-61: Internet Protocol (TCP/IP) Properties Dialog BoxGeneral Tab
4. Under the General tab of the Local Area Connection Properties dialog box, click the connection Internet Protocol (TCP/IP) (Figure 8-61). 5. Click the Properties button. > The Internet Protocol (TCP/IP) Properties dialog box is displayed.
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Networking
Figure 8-62: Local Area Connection Properties Dialog BoxAdvanced Tab
6. Under the Advanced tab of the Local Area Connection Properties dialog box, in the Windows Firewall group box, click the Settings button (Figure 8-62). > The Windows Firewall dialog box is displayed. 7. Under the General tab of the Windows Firewall dialog box, make sure the Dont Allow Exceptions box is not checked.
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Figure 8-63: Windows Firewall Dialog BoxExceptions Tab
8. Under the Exceptions tab of the Windows Firewall dialog box, check all the pcAnywhere... and Remote... boxes (Figure 8-63). 9. Click OK. 10. Click OK repeatedly to close the LAN setup.
Testing Network Communication with Peripherals

If your handler has peripherals such as an inspection camera and/or laser, you can test the TCP/IP connections from the Exatron PC to the laser or camera. To test TCP/IP connections: 1. Close all application programs. 2. Click the Start button at the lower left corner of the screen. Click Run.
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Networking
Testing Network Communication with Peripherals
Figure 8-64: Selecting Run Option
3. In the Run dialog box, type cmd.exe and click OK.
Figure 8-65: Opening a DOS Window
4. In the DOS window that opens, at the C:\ prompt, type PING followed by a space and then the IP address of the peripheral you want to test communication with. This example uses the following IP addresses: PING 192.168.10.111 for the camera, or PING 192.168.10.112 for the laser.
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Figure 8-66: PING Command with Replies
> You should see a series of replies like the ones shown in Figure 8-66. All packets sent should have been received, with none lost. 5. To show the IP address of the host (Exatron) PC, in the DOS window type IPCONFIG /ALL.
Figure 8-67: IPCONFIG Command with Reply
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Networking
Remote Handler Control with WebEx
> You should see information similar to that shown in Figure 8-67. The host (Exatron) IP address in this example is 192.168.10.110.

The engineers at Exatron can help you diagnose handler problems with your Internet connection and the WebEx Internet service. When you contact Exatron for troubleshooting, you may receive an e-mail inviting you to a WebEx meeting (Figure 8-68).
Figure 8-68: E-mail Invitation to WebEx Meeting
To join the meeting, just click the link that is displayed in the e-mail message and follow the instructions shown.
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Figure 8-69: WebEx Meeting Information
If you have any problems, click on the help link from WebEx at the bottom of the e-mail. Their support is thorough.
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Replacing Exatron Program File with an Upgrade

Upgrades to the Exatron program software may be done in order to add or remove features or functions, or to debug the main system controller software. The Exatron program is a file named [YourCompany]_[Model#]_[suffix]_[date_time]_[version].exe where the date, time, and version of the latest upgrade are included in the filename. It is located on the CPU in the directory C:\Exatron\ . It is important to maintain a backup of all files previously used and tested. If a newly updated file won't perform properly, a copy of the backup may be reinstalled back into the proper working directory. CAUTION: Do not delete the 3 essential system files: WinIO.dll, WinIO.sys, and WinIO.vxd (Figure 8-70).
Figure 8-70: Exatron Directory with Job Files, 3 Essential System Files, and Existing Program File
Following this procedure will insure that a backup is maintained of the original and all subsequent upgrades. CAUTION: Do not delete any previous zip files from the Backup directory. Always maintain an additional up-to-date copy of all the contents in the C:\Exatron\Backup\ directory on external media such as a CD-ROM or a set of floppy disks. Exatron may send zip files by e-mail with modified file extensions so the files don't get stripped or blocked by the firewalls at client sites. Prior to extracting from these files, rename the zipped file, changing the extension back to *.zip. To install the Exatron software: 1. Close all applications and open Windows Explorer to navigate and edit file directories. 2. Copy the current Exatron program file into the C:\Exatron\Backup directory.
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3. Copy the .edf or .job files for the jobs/setting files you are currently running into the same Backup directory. Rename these backup files to include date and time in the file name so you can identify and reuse these files if necessary. 4. In the C:\Exatron\ directory, delete the [YourCompany]_[Model#]_[suffix]_[date_time]_[version].exe file. (A backup is already in the C:\Exatron\Backup\ directory.) 5. Copy the attached .zip file into this same directory (C:\Exatron\Backup).
Figure 8-71: Backup Directory with Job Files, Old Program File, and New Zipped File
6. Double-click on this new *.zip file and extract it into the directory C:\Exatron\ where the previous program file was deleted. It has a newer date/time/version than the previous program file.
Figure 8-72: Exatron Directory with Job Files and New Program File
Typically a shortcut is placed into the C:\Documents and Settings\All Users\Start Menu\Programs\Startup directory so that this program will automatically launch when Windows is started. This shortcut must be replaced with a shortcut pointing to the new program file. 7. Right-click on the filename and select Create Shortcut from the context menu to make a shortcut for the new file.
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8. Click and drag the shortcut (not the original file!) into the directory C:\Documents and Settings\All Users\Start Menu\Programs\Startup. 9. Copy this shortcut to the desktop and delete the old shortcut. 10. Restart appropriate applications, or restart the CPU and the applications will automatically start. The new executable program file is ready to use. When an original .edf or .job file is opened using this new program file, you may see an error message: Unexpected file format. If this happens, it is because the new program file contains new data fields that require values from the job file, so the job file is not properly formatted.
Figure 8-73: Error Message
To reformat the job file: 1. Click OK in the error message dialog box. 2. Click the Diagnostics button and check the various windows for new fields. 3. Enter valid data in any new fields or input boxes. 4. Finally, save these settings before exiting the program. Bacause you have saved the new variable into this .edf or .job file, the next time you open this .edf or .job file, the Unexpected file format error will not appear.
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Troubleshooting
The following are problems that have been encountered occasionally, and their solutions.
Motors Move Very Slowly

If the motors seem to be moving too slowly, reboot the computer.
System Does Not Pick Up Devices Reliably

If the system is not picking devices out of the input, there are several possible causes: Pickup height (Z-pick) is not set correctly in the Exatron software. > If a new type of device is used, the pickup height previously programmed may be wrong. Ideally, the bottom of the suction cup should be about .050" (1.2 mm) from the top of the device before the rub cycle. If the gap is significantly larger or smaller (.015" or more), then the software setting in the Exatron software should be adjusted accordingly. Vacuum cup is dirty or worn out. > Check the vacuum cup. Visually inspect the suction cup to make sure it is physically intact, i.e., no tears or chunks missing. Then, using a cotton swab dipped in isopropyl alcohol, clean the inside surface of the suction cup bellows. Vacuum adjustment is wrong. > The Model 7000-BPR has a vacuum sensor that tells the system when a vacuum is detected, which means there is a part seated on and being held by the vacuum cup. The vacuum sensor has a small LCD display which shows the strength of the vacuum, as measured in centimeters of mercury (cmHg). The sensor is set at a given measurement, and when the actual vacuum measured in the sensor is higher than that number, it tells the system a part is captured. To determine the set point, flip the small switch on the vacuum housing to "SET." Then, with the switch back at "RUN," press the vacuum override button on the side of the handler near the vacuum sensor assembly. This will draw a vacuum and the sensor will show the measurement. Block the pickup head manually with a device to see that setting. The actual measurement should be at least 10 cmHg above the set point. You should see a red light illuminate on the vacuum sensor when a vacuum is measured at or above the set point. Typically, the set point will be around 50 cmHg and the actual measurement with a device present will be around 60 - 65 cmHg. If your numbers are significantly different than these numbers, you should carefully inspect the rest of the pneumatic system for blockages, breaks, etc., as explained next.
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Troubleshooting
System Does Not Pick Up Devices Reliably
Air lines blocked or broken/worn/disassembled. While unlikely, it is possible for the air lines to become broken, blocked, or otherwise rendered non-functional. This can happen due to wear, particulate or liquid contaminants in the air supply lines. > Check all air fittings to assure the air tubing is well seated in the fitting. > Visually inspect all the air lines and the incoming air regulator assembly for wear, discoloration or cracking. Replace any air line that appears compromised. Check for liquid in the reservoirs of the incoming air regulator. If either is full, you must remove the regulator from the system and drain the unit. Disconnect the incoming air supply and tip the unit to allow liquids to drain out. Exatron strongly recommends replacing the regulator unit if this problem happens more than once. Moreover, the customer should improve the incoming air supply to ensure it is clean and dry. Blow-off is not working properly. In addition to creating the vacuum, the vacuum generator unit also acts as a regular air valve. The Model 7000-BPR relies on this feature to send a blast of positive air pressure through the vacuum line in order to break the residual vacuum pressure after the vacuum is turned off. Without the blow-off, it is possible for devices to stick to the pickup head due to this residual vacuum. > Test the blow-off function by pressing the blow-off override button on the side wall of the handler base near the vacuum generator unit. A small positive air flow should be felt at the suction cup. If no pressure is felt, the unit may be malfunctioning or set too low. > A small adjustment screw can be found on the vacuum generator unit which will increase or decrease the blow-off pressure. Care should be taken when adjusting this screw, as loosening it will have the effect of increasing the blow-off pressure, but if the screw is turned too much, it will come out and render the blow-off inoperable. See "Adjusting Pickup Nozzle Blow-Off" on page 8-29. Pickup head shaft is loose and out of position. > The pickup head shaft is retained by a clamp at the top of the Y gantry unit. If this clamp is loose, it is possible for the shaft to "migrate" up, thus eventually getting out of position. If this happens, the shaft can be pushed back down and re-tightened, or tightened in the new position and the various job software settings adjusted accordingly. The first course of action is preferable but must be done carefully. In most cases, the migration will be no more than .050" and so only a small adjustment must be made. If the adjustment makes the head too low, it may place unacceptable pressure on the devices in the trays. Thus, make a very small adjustment and test the new setting to see if it picks up devices. Watch carefully for over-travel.
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Chapter Overview
This chapter discusses the following main topics: Topic Obtaining Replacement Parts Guide to the Parts List List of Parts Page 9-1 9-4 9-6
Obtaining Replacement Parts

Spare parts can be obtained from Exatron. It has always been Exatron policy to support all the equipment we have ever manufactured. If the part is still available, or can be made, we will get it for you. In most cases, faxed requests and shipment of replacement parts orders are processed within twenty-four hours of receipt by Exatron. The following sections discuss things to note when ordering replacement parts.
Suction Cups
Exatron stocks three sizes of anti-static silicone suction cups for the Model 7000-BPR: 4 mm, 6 mm, and 8 mm diameter. The correct size for a given suction cup will depend on the size of the device. Choose a suction cup so that when the vacuum is applied the edge of the cup is at least .020" from any edge of the device (or leads if the device is dead-bug). Keep in mind to use the largest cup that fits this requirement. Exatron part numbers are: 2mm: PNE042-412 4mm: PNE042-414 6mm: PNE042-416 8mm: PNE042-418
The 2 and 4 mm cups fit over one mounting stud, while the 6 and 8 mm cups require a different stud. In most cases, Exatron systems ship with the correct stud for the 6 and 8 mm cups. These studs can be purchased separately, and come with either a 2 mm, 4 mm, or 6 mm cup attached. The part numbers are:
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Stud with 2 mm Cup: PNE042-402 Stud with 4 mm Cup: PNE042-404 Stud with 6 mm Cup: PNE042-406
Vacuum Generator Air Filter

The vacuum generator air filter must be replaced when it is visibly dirty or contaminated. The Exatron part number is PNE022-020.
Z Chain
This is a 70-link hard plastic chain or belt. The Exatron part number is BEA12-003.
Hose Sizes
Hoses are ESD (electro-static discharged) for handler safety. The size is stamped on the hose: 5/32" or 1/8" or 1/4" or 3/8", to enable you to order the right size.
Relays
The mechanical relay (or contactor) inside the Exatron PC acts as a safety circuit; it cuts power when necessary. When changing out to a new one, make sure you order the right one, either 12 volt or 24 volt (Figure 9-1).
Figure 9-1: Relays12-Volt (Left); 24-Volt (Right)
Motor Controllers
When ordering Cool Muscle motors, be aware that master and slave motors are somewhat different. The master has a secondary circuit board piggybacked on top; the slave does not (Figure 9-2). Exatron recommends that you order a master, because you can use a master as a slave if it becomes desirable; but you cannot use a slave as a master.
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Obtaining Replacement Parts
Motor Controllers
Figure 9-2: Cool Muscle Motor ControllersSlave on Left; Master on Right with Piggybacked Board
Figure 9-3: Cool Muscle Motor ControllersSlave on Left, Master on Right; Jumpers in Opposite Configurations
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Notice that the jumper configurations are different for the master than for the slave. The slave has the black jumpers all the way to the left; the master has them all the way to the right (Figure 9-3). These jumper configurations can be changed just by pulling them off and replacing them on different pins.
Guide to the Parts List

This guide shows how to use the parts list to determine the exact part number of any custom part in your machine in order to replace it if necessary. The parts list contains the items that Exatron has custom manufactured. They include machined parts, sheet metal, printed circuit boards, cables, and standard vendor parts that have been modified by Exatron. A limited number of standard vendor parts are also listed here. The title shown at the top of the list indicates the type of parts list. This should match your system's hardware. The parts list may change as Exatron improves each model with each new generation. If you have different generations of the same model, the parts lists will vary. Whenever possible, Exatron makes design improvements capable of being used in older versions of the same model. The date on the parts list indicates the date of the last revision of the list, not necessarily the last revision of the system hardware. An explanation of the column categories in the parts list follows.
Exatron (Part Number)

The first column contains the number assigned by Exatron to a specific part; for example, 8000-D14 or PET-R44. The part number usually has two sections or number/letter sets. The first set of alphanumeric characters (e.g. 1900, 8000, PET, TAPE) indicates the model number of the system for which the part was originally designed. We use designs of parts from different models to lower inventory costs and to speed the design of custom handlers. The next three alphanumeric characters (e.g. 906, C06, P14) are simply the numerical count of the part as it was designed. These are the three characters that are stamped or laser marked onto most machined parts. Exatron occasionally uses additional letters or numbers to indicate special features. We use R and L to specify right and left hand parts. AM or HR will indicate parts for Ambient Machines or Hot Rails. We use 62 or 75 to indicate specific sizes of solenoid plungers. There are other special notations that may be used as part of our numbering system and that may change with time. Please contact the Exatron factory for assistance with any questions regarding special letters or numbers attached to part numbers.
Part Quantity Columns

The next two or three columns indicate the quantity of the specific part used in the manufacture of this system. This information may be useful in determining the correct part number and was used to build an assembly kit when your system was originally built.
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Guide to the Parts List
Manual
Manual
Each row that has a 1 in this column has a corresponding wiring print in this manual. The print is identified by the part number.
Description
This is the name assigned to the part. In most cases, this description will clearly designate the part you wish to locate. Please include this description when ordering replacement parts.
Assembly
This column indicates which major system sub-assembly the part belongs to. In most cases, the "Assembly" can be ordered as a complete replacement part.
Size
These are dimensions in inches. The dimesions are listed left to right from smallest to largest: A x B x C. This is the starting size of the part prior to being machined.
C B A
Figure 9-4: Dimensions Listed From Smallest to Largest
Imagine a cube drawn around a part you are trying to identify. The dimensions of this cube can be checked against this size dimension and may be of assistance in determining a required part number. When the parts list indicates another Exatron part number in the size column, then the part was made by modifying an existing Exatron part. The modification is required for this handler only. When ordering replacement parts, be sure to use the part number and not the size. If the size column contains SEE PRINT, then the part is made from sheet metal or a PC board, or is something which is not made from a solid cube of material.
Finish
This column designates the finish used on the part. The following list is in alphabetic order. ALODINE: A non-anodic protective coating, a microscopic thin film commonly prescribed on aluminum to provide increased corrosion resistance and impose desired electrical resistance characteristics. BLACK: Black anodizing.
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BLUE: Blue anodizing. CLEAR: Clear anodizing, silver in color. HCR: Non-conductive, hard finish, dark green in color. NEDOX: Conductive, hard finish, silver in color, that eliminates static build-up and provides good electrical conductivity. Aluminum parts coated with nedox exhibit the hardness of steel without the weight. The finish protects against abrasive wear and corrosion. The dry-lubricated, non-stick surface also reduces friction of moving or sliding parts. NICKEL: Bright nickel plating, silver-chrome in color. NONE: No finish, natural material. PAINT: Painted part; colors may be beige, black or blue. RED: Red anodizing.
List of Parts
A parts list specific to each handler is included with each manual. See the following inserted pages.
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Chapter 10: Prints

A set of prints specific to each handler is included with each manual. See the following inserted pages. Additionally, an optional seismic tie-down kit is available from Exatron (see Figure 9-1 on page 9-2). Call for a quote.
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Chapter 10: Prints
Figure 10-1: PET-V84-B
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Appendix A: Test Interfaces

Chapter Overview
This chapter discusses the following main topics: Topic Components of Test Interfaces TCP/IP Interface TTL Handler Port Interface Serial Port Commands Exatron RS-232 Commands Exatron Plus RS-232 Commands Serial Commands for Multiple Test Sites with One Serial Port GPIB Test Interface Decimal-Hexadecimal-Binary-ASCII Conversion Table Setting Up HyperTerminal Page A-1 A-3 A-4 A-8 A-9 A-11 A-17 A-20 A-23 A-25
NOTE: All the interface types discussed in this chapter are options. No one interface type is included automatically. Whereas every handler has an RS-232 port and an ethernet port (hardware), the software drivers and the interfaces used for your handler will depend on your needs and the features you order.
Components of Test Interfaces

Every test interface has 2 parts: DUT Controllers
DUT InterfaceHardware
DUT (Device Under Test) interface connects the handlers test contacts to the testers test socket. A direct dock interface provides the best performance, although other interface methods are available.
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Chapter A: Test Interfaces
Control InterfaceMethod of Communication

The control interface allows the handler to send a Start to the tester and subsequently allows the tester to instruct the handler how to process the device under test. The means of access include: Exatrons TTL "Handler Port" An RS-232 serial port The tester sort signals will come into the handler via either the handler port or the RS-232 port. Protocols available from Exatron include: TTL (always available) RS-232 RS-485 GPIB
Some factors to consider when selecting a protocol include: Serial cable RS-232 interfaces between only 2 entities, but RS-485 allows a daisy chain configuration among multiple entities. These two protocols use slightly different hardware. If a tester uses RS-485, it may not work with Exatrons RS-232. The GPIB language set is quite complex. Its customization for your needs requires a separate quote. The protocol for each handler is custom-designed for the handler and the tester it will use. There are many options that can be selected to customize this interface to your specific application. Each handlers interface is specific to that handler, but it is usually a variation of the RS-232.
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TCP/IP Interface
Control InterfaceMethod of Communication
Serial ports Serial ports
Handler port
Figure A-1: Ports
In the example in Figure A-1, the Handler Port uses TTL.
Distinguishing Features of Control Interfaces

Control Interface
Port type/category of interface Number of pins/wires on connecter Communication type TTL 24 Hi/low signal (+5v/0v)
TTL
Serial 9
RS-232
ASCII character string
TCP/IP Interface
With the TCP/IP protocol interface, the handler acts as the client, and the tester acts as the server. To use this interface, the tester software is opened first. The tester software waits for the Winsock connection over the ethernet from the handler software. After the tester software is running, the Exatron software is opened. The Exatron software connects through Winsock with the tester PC. They use standard serial commands.
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TTL Handler Port Interface

This interface is an option on Model 900 handlers. It is not always installed. There are some other seldom-used options that might not allow this interface to be installed. If this interface is required, it should be installed while the handler is still at Exatron. The TTL Handler Port interface uses simple +5 volt TTL-compatible signals to control the handler. This specialized parallel port interface uses an optional 24-pin "D" connector on the back of the control PC (Figure A-2). It has been designed to be compatible with all Exatron gravityfeed Model 2000, 3000, 5000, and 6000 handlers.
Figure A-2: 24-Pin D Connector on Handler
The TTL Handler Port on a Model 900 is connected inside the control PC to Port #3 on the 902 I/O PCB, PET-C06. On handlers with PET-C06 Rev A to Rev E, this Port #3 is not protected with opto-isolation. On these older revisions of PET-C06, use cable PET-G70-C which removes the handler +5 VDC from the 24-pin D connector. Connecting the handler's +5 VDC to the tester's +5 VDC is not allowed. Connecting the Tester +5 to the Handler +5 will result in a blown-up PET-C06 PCB, which is not covered by the handler's warranty. Handlers equipped with PET-C06 Rev F or newer 902 I/O PCBs use an opto-isolated Port #3 (Figure A-3). It is highly recommended that when the TTL Handler Port interface is required, older handlers be upgraded. Handlers with opto-islated Port #3 use cable PET-H07-A or newer. The opto-isolated TTL interface will require tester-supplied +5 VDC and tester-supplied ground to be functional. Never connect the handler's +5 VDC or +24 VDC supplies to anything other than the handler.
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Start Test Output
Figure A-3: TTL 24-Pin Connector with Pin Designations
Start Test Output

The handler moves a device into the test site. After allowing time for the device to settle, the handler issues a start-test pulse (Pin 10) to the tester. The start-test pulse width is pre-set to 50 milliseconds. This pulse is normally High (+5) and goes Low for the pulse width. There are optional outputs that may or may not be used in special cases.
Sort Test Result

To complete the test, the tester must send back one of eight sort signals. These signals must be normally High and go Low for at least two milliseconds. The sorts must appear on Pin 1 through Pin 8 on the handler port connector. We recommend that you use Pin 1 for PASS and Pin 2 for FAIL when using the handler in PASS/FAIL applications. The Input Sort is connected to a latch. The latch sets on the falling edge of the sort signal. Make sure that your interface does not allow fast glitches which may become latched, causing the handler to mis-sort.
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End of Test
If desired, you can request an "End of Test" be added to your handler software. In this case, the End of Test signal will be connected to Sort 8 on the 24-pin D connector. The End of Test and just one of the other 7 sorts must be low at the same time, for at least 2 milliseconds.
Handler Port Diagnostics

The Sensor/Solenoid Check window in the Exatron Diagnostics software allows the user to test the TTL handler port Inputs and outputs.
Handler Port Simulator

An optional 8-bit LED Checker (#3000-521; see Figure A-4) is available from Exatron that will allow the user to test the TTL Handler Port. This "blue box," as it is referred to at Exatron, will allow the user to test the handler I/O and can be used as a simulator. You can operate the handler without the tester connected. It also has LEDs connected to each input/output. This will help troubleshoot any interface problems. You can see the LEDs blink or not when a signal is either sent or received.
Figure A-4: Eight-Bit LED Checker #3000-521
For PET-C06 Rev F I/O PCB's with opto-isolation, it is necessary to use an extension cable with the LED checker that allows the handler's +5 VDC and Ground to be connected.
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Handler Port Simulator
Figure A-5: TTL 24-Pin Connector with Pin Designations
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Serial Port Commands

Unless specifically requested, all RS-232 ports are set to: Alphabetic command Baud = 9600 Databits = 8 Stop bit = 1 Parity = N (none)
All commands are standard uppercase ASCII characters. Typically, a NULL modem, female/female, 9-pin RS-232 cable is required for each port. The testers should always include a "\r" carriage return after every command. The handler will send a "\r" after every response. The RS-232 serial ports use only 3 wires to transport ASCII, or serial strings: Send Receive Ground
Figure A-6: Typical RS-232 Interface Cable
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Exatron RS-232 Commands
Beginning the Connection
Exatron RS-232 Commands

NOTE: These are standard ethernet commands, used over an ethernet cable. The following is a definition of a standard RS-232 control interface from an Exatron handler to one or more testers. Each tester is controlled by its own RS-232 port, thus: 1 tester = 1 port, 2 testers = 2 portsup to 16 ports. This interface can also be used by a single tester with multiple test sites. Using separate RS-232 ports for each test site makes it very easy for the handler to keep track of the status of each test site. For single testers using only one RS-232 port, but with multiple test sites, Exatron has a different RS-232 command set. See "Serial Commands for Multiple Test Sites with One Serial Port" on page A-17.
Beginning the Connection

Once the handler is powered up, all motors homed, and a job is loaded, the operator can start the handler. The handler will send a "H\r" before it picks up the first device to be tested. The tester should respond with a "R\r" if it is completely ready to start testing. Handler sends to the tester: "H\r" (Handler ready to cycle) Tester sends back: "R\r" (Tester is ready to test) > If nothing is received back from the tester, the handler will time out and display an error message. The operator should check that the tester is in fact ready to test and that all cables are properly plugged in. > If the tester sends back an unrecognized answer, the handler will display an error message, and if possible, display what was sent by the tester. Tester sends: "EOL\r" (Command to stop getting device from input; this is optional command) Handler sends: "EOL\r" (Signal that handler finished getting device from input; this is optional command)
Starting the Test

Once the handler receives the "R\r", the handler will pick up a device and place it in the test socket. Once the device is fully clamped in the test socket, the handler will send a "S\r". The tester should start its test.
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After the Test Is Completed

Once the tester has completed its test of a device, it needs to send back a Sort Command. The handler will accept up to 8 sorts from the tester. Typically a sort "1\r" is a pass and all other sorts are types of fails. Exactly which sorts mean pass/fail/tape/tube/bucket outputs depend on the options your handler is equipped with. Use the handler's setup software to define the meanings of each sort for your specific application. "1\r" "2\r" "3\r" "4\r" "5\r" "6\r" "7\r" "8\r" = = = = = = = = Sort #1 Sort #2 Sort #3 Sort #4 Sort #5 Sort #6 Sort #7 Sort #8
Once the handler receives the sort command from the tester, the handler picks up the now tested device and sorts it to the predetermined output. This completes a normal test cycle. The handler will move over the next untested device to be picked up and sends a "H\r" to the tester and a new cycle is started. Handler sends: "INPUT_TRAY_EMPTY\r" (Handlers input is empty; it displays message to load more devices)
Cycle Summary
For each cycle, the following exchange occurs. Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready) Tester sends: "EOL\r" (Stop getting device from input) Handler sends: "EOL\r" (Finished getting device from input) Handler sends: "S\r" (Start test) Tester sends: "1\r" (Sort 1) or "2\r" (Sort 2) or "3\r" (Sort 3) or "4\r" (Sort 4) or "5\r" (Sort 5) or "6\r" (Sort 6) or "7\r" (Sort 7) or "8\r" (Sort 8)
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Exatron Plus RS-232 Commands

The Exatron Plus interface is an extension of the standard EXATRON RS-232 interface. The user will be able to select either Exatron or Exatron Plus interface. If you want to implement the Exatron Plus interface, contact Exatron at 800-EXA-TRON. In addition to the command exchange explained under "Exatron RS-232 Commands" on page A-9, the Exatron Plus interface will have the following enhancements:
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Command Meaning *\r Remote reset Explanation At any point the tester can send a "*\r". When the handler receives an asterisk it will immediately stop its current operations. The handler resets as if the handler has just powered up. Any devices in any of the test sites will be automatically removed and placed in the Dump tray. The handler is equipped with a dump tray on the end of the first X1 tray. The tester can send a "?\r", to the handler to cause the handler to place the tested device in the dump tray. No count is maintained for the dump tray. The operator also needs to keep the dump tray empty to prevent devices from piling up on one another. The dump tray is basically a bucket sort. If at any time a retest is required by the tester, the tester can send back a "0\r". The Handler sends: S\r" (Start test) handler will do one of the following, depending on the type of test socket being used: Tester sends: 0\r" (Retest with mechanical Pick up the device and reseat it socket cycle) Open and close the open top socket, or Cycle the hold-down plunger Handler sends: S\r" (Start test) Tester sends: 0\r" (Retest with mechanical The handler will then send a new "S\r" command to the tester. This cycle can be socket cycle) done over and over as many times as required by the tester. The handler will not Handler sends: S\r" (Start test) sort the tested device until a correct sort command is received. Tester sends: 1\r" (Sort 1) (Sort the nowtested device) Example
?\r
Send to dump tray sort
0\r
Remote retest sort
9\r
Return to If the handler receives a "9\r" for a test sort, the handler will return the device to the pickup sort exact pocket it was picked up from. If the pocket to return to already has a device, which is remotely possible in some configurations, the device will be sorted to the dump pocket on the end of tray #1. Pause han- At the start of any cycle, the tester can send a Pause command to the handler. Handler sends: H\r" (Cycle?) dler When the handler receives a "P\r", the handler will stop cycling and post a message Tester sends: P\r" (Pause handler) to the operator. The handler will remain paused until the operator restarts the handler's operation from the handler's control panel. Once the handler is restarted, it will continue with its operations from the point it left off.
Cycle Summary
P\r
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Command Meaning Z\r Zero all counts Explanation Example
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At the start of any cycle, the tester can send a zero all counts command to the han- Handler sends: H\r" (Cycle?) dler. This command is typically to be used at the start of a new lot of devices. The Tester sends: \r" (Zero counts) handler will send "H\r" to the tester. The tester will send back a "Z\r" to the handler. The handler will stop and display an Are you sure message to the operator. The operator will be given the opportunity to either reset all counts to zero or to continue on with the cycle with counts saved from the previous cycle. The handler will also give the operator an opportunity to reload or replace any trays of devices in the handler.
X\r
Disable socket
This is a way to have the handler "skip" any combination of test sockets, on the fly, Handler sends: "H\r" (Cycle?) when testing with more than one test socket. Tester sends: "X\r" (Skip cycle) The handler will move on to the next cycle for The handler will send a "H\r" at the start of each subsequent cycle. To permanently the next test site. have the handler skip a test site requires changing the handler's set up before starting any test cycles. This command allows the tester to remotely send the handler into an end-of-lot Handler sends: "H\r" (Cycle?) cycle. The handler can also be sent to an end-of-lot cycle from its control panel by Tester sends: "E\r" (End Of Lot, stop cycle) the operator. Handler sends to the tester: "H\r" (Handler ready to cycle). The tester sends back a "E\r" (End Of Lot) The handler will go into its end-of-lot cycle. On single test site handlers, the handler will simply stop testing and display the End Of Lot message to the operator. On handlers with multiple test sites, the handler will stop loading untested devices. It will then either: Automatically remove any devices still being tested and return them to the same place they were picked up from, or Finish any devices still being tested and sort as required. The user can go to the handler's set up to select one of these two options for end-oflot test socket unloading. Once all sockets are emptied the handler will display the End Of Lot message to the operator and stop cycling.
E\r
End of lot
If the operator should go to end-of-lot from the handler control, the handler will stop loading untested devices. It will then do one of the two things just described. The user can go to the handler's setup to select one of these two options for end-of-lot test socket unloading. Once all sites are empty, "E\r" will be sent by the handler to every test site. No response is required back from any of the testers.

Command Meaning G[a][n]\r Explanation Example Handler sends: "H \r" (Cycle?) Tester sends: "GA1\r" (Test Golden Unit from pocket A at test site 1)
01/2011 Copyright Exatron, 2011
Golden Unit If the handler is set up with a Golden Unit Tray Option, this exchange is used. cycle The handler sends the preliminary handshake: "H\r". The tester sends a response like "GC2\r" specifying the source pocket from which to get the Golden Unit, and the destination test site into which to put it.
(The unit specified may be any Golden Unit from A to G, and may be designated for any The handler picks up a device and places it in the test socket specified by the tester. test site available, thus: GA2, GG1, GF2, etc.) Once the device is fully clamped in the test socket, the handler sends a command to start testing that designates the same test site requested by the tester, like "S2\r". Handler places unit, sends: "S1" (Start testing at test site 1) Once the tester has completed its test, it needs to send back a Sort command, like "1\r" or "7\r". The handler accepts any of 8 sorts from the tester. The handler then Tester finishes test, sends sort result: picks up the device and places it back in the pocket where it was picked up, regard- "1\r" less of the sort received from the tester. This completes a Golden Unit test cycle. Handler retrieves unit into original pocket. The cycle repeats, beginning with the tester sending another source-to-destination command, like "GD1\r". Tester sends another test request: "GB2" Handler sends: "H \r" (Cycle?) Tester sends string: "T ## _ R # # _ C # #\r" where: T (Tray) # (Tray carriage number, 1 to 5) # (Sub Trayuse 0 for JEDEC trays; use 1 to 8 for 2"/4" waffle packs) The user must select either sequential input pick up or "Pick Up Specific _ (Underscore) Device" prior to cycling the handler. The two choices cannot be intermixed in R (Row) a given setup. Either the handler is in control or the tester is in control. # (Row number, use 0 for rows 1 thru 9) # (Row number, 1 to 9) The handler will go to the specified pocket and attempt to pick up the device. If a _ (Under score) device is found the device will be loaded into the test socket and a test cycle will be C (Column) started. If no device is found, the handler will pause, display an error message, and # (Column number, use 0 for column 1 thru 9) then automatically return to the start of the next cycle. # (Column number, 1 to 9) \r (End of string) At the end of test, the tester can either send the now-tested device back to the pocket it was picked from, or sort it normally. See the above sort commands for details.
T ## _ R # Pick up # _ C # #\r specific device
The handler can be commanded to pick up any device, from any pocket, from any input tray. This is an option that must be selected prior to cycling the handler. The handler will normally pick untested devices from the first left hand pocket of an input tray and then automatically index to the next pocket or tray until all input pockets are emptied or until the handler reaches a predetermined number of empty pockets in a row.
Cycle Summary
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Command Meaning TRAY <SP> FULL\r Explanation Example
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Output tray At some point the handler output tray(s) will reach its last pocket. The handler will full stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "TRAY <SP> FULL\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point: The operator can choose to go into an end-of-lot cycle as described above. The operator can reload empty tray(s) as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tape Some handlers are equipped with optional output tape-and-reel assemblies. At full some point the taper will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T A P E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new supplies or a new empty reel as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester. Output tube Some handlers are equipped with optional output tube holders. At some point the full tube(s) will reach its preset full count. The handler will stop and display a message to the operator. The handler will also be at the start of the next cycle at this point. The handler will send: "T U B E <SP> F U L L\r" to the next test socket to be loaded. No answer is required from the tester. This string will be sent only to the next test socket/tester. The operator will be given several choices at this point. The operator can choose to go into an end-of-lot cycle as described above. The operator can reload new empty tubes as required. Then a new cycle can be started by the operator. A new "H\r" will be sent to the test socket/tester.
TAPE <SP> FULL\r
TUBE <SP> FULL\r

Command Meaning Explanation Example
01/2011 Copyright Exatron, 2011
S ## _ R # Device out- The handler can be preset to attach the output sort location of each device just after TRAY outputs example: # _ C # #\r put sort the device is placed in its output. This option must be turned on or off in the hanS12_R01_C23\r location dler's setup prior to cycling. S (Sort) # (Tray carriage number, 1 to 5) After the handler drops off a tested device into the tray, it can be preset to send back # (Sub Trayuse 0 for JEDEC trays; use 1 to the following string "S ## _ R # # _ C # #\r". See example for bucket, tape & reel, 8 for 2'/4" waffle packs) and output tube sorting responses. _ (Underscore) R (Row) No response is required back from the tester for any of these messages. The han- # (Row number, use 0 for rows 1 thru 9) dler then moves on to the next cycle. # (Row number, 1 to 9) _ (Underscore) C (Column) # (Column number, use 0 for column 1 thru 9) # (Column number, 1 to 9) \r (End of string) BUCKET outputs example: B1\r B (Bucket) # (Bucket number) \r (End of string) TAPE-AND-REEL outputs example: T256\r T (Tape) # (current pocket count) # # # \r (End of string) OUTPUT TUBE outputs example: O3_15\r O (Output tube) # (Tube number) _ (Under score) # (current pocket count) # # \r (End of string)
Cycle Summary
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Command Set Summary

If at any time the tester sends: " *\r" (remote handler reset) Cycle start: Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready; handler then begins normal cycle) or Tester sends: "P\r" (Pause handler) or Tester sends: "E\r" (End Of Lot, stop cycle) or Tester sends: "X\r" (Skip cycle/test site) or Tester sends: "Z\r" (Zero counts) or Tester sends: "GA1\r" (Test Golden Unit A at test site 1) GB[n]\r" (Test Golden Unit B at designated test site) GC[n]\r" (Test Golden Unit C at designated test site) GD[n]\r" (Test Golden Unit D at designated test site) GE[n]\r" (Test Golden Unit E at designated test site) GF[n]\r" (Test Golden Unit F at designated test site) GG[n]\r" (Test Golden Unit G at designated test site) or Tester sends: "T ## _ R # # _ C # #\r" (Pick up specific device) Test cycle: Handler sends: "S\r" (Start test) Tester sends: "1\r" (Sort 1) "2\r" (Sort 2) "3\r" (Sort 3) "4\r" (Sort 4) "5\r" (Sort 5) "6\r" (Sort 6) "7\r" (Sort 7) "8\r" (Sort 8) "9\r" (Return to pick up) "0\r" (Remote retest) "?\r" (Send to dump tray; no count is maintained for dump tray) At device output drop off/sort: Nothing is sent back to the tester as a standard setup.
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Serial Commands for Multiple Test Sites with One Serial Port
Command Set Summary
No response is required back from the tester. Other possible handler start of cycle messages: Note: none of these messages require a response back from the tester. "TRAY FULL\r" "TAPE FULL\r" "TUBE FULL\r" "E\r" (End Of Lot)
This interface is an extension of the standard EXATRON RS-232 interface. NOTE: If you want to implement this interface, contact Exatron at 800-EXA-TRON. This interface requires optional test site hardware and software. In addition to the command exchange explained under "Exatron RS-232 Commands" on page A-9, this interface has the following enhancements:
Command Set Summary

Cycle Start: Handler sends: "H\r" (Cycle?) Tester sends: "R\r" (Ready, handler begins normal cycle) Handler sends: "S1\r" (Start test site 1) Handler sends: "E1\r" (Request for end-of-test result from site 1) Tester sends: "1B\r" (Test site 1 busy) > If testers reply is busy, the handler pickup nozzle moves to another test site and sends another "E[n]\r" request; for example, "E2\r". > The handler will later issue a new "E1\r" when the pickup nozzle has moved back to test site #1 and is ready to sort test site #1. If test site #1 is not busy, it sends one of the following signals. Tester sends: "11\r" (Site 1 sort 1) or "12\r" (Site 1 sort 2) or "13\r" (Site 1 sort 3) or "14\r" (Site 1 sort 4) or
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"15\r" (Site 1 sort 5) or "16\r" (Site 1 sort 6) or "17\r" (Site 1 sort 7) or "18\r" (Site 1 sort 8) or Tester sends: "10\r" (Retest test site 1) Note that the tester can send a result only from the test site queried by the handler. For example, if the handler request is "E4\r" for test site 4, then the response must be from test site 4. The interchange would be as follows: Handler sends: "S4\r" (Start test site 4) Handler sends: "E4\r" (Request for end-of-test result from site 4) Tester sends: "4B\r" (Test site 4 still busy; handler pickup nozzle then moves to another test site) or Tester sends: "41\r" (Site 4 sort 1) or "42\r" (Site 4 sort 2) or "43\r" (Site 4 sort 3) or "44\r" (Site 4 sort 4) or "45\r" (Site 4 sort 5) or "46\r" (Site 4 sort 6) or "47\r" (Site 4 sort 7) or "48\r" (Site 4 sort 8) or Tester sends: "40\r" (Retest test site 4) As the handler is at various times in a mechanical position to remove devices from any of the test sites, the handlers start test and its request for test results may not be in the order of E1, E2, E3, E4. Rather, the requests may come in any order: E3, E2, E4, E1. The reply from the tester must be concerning the test site specified by the handlers request.
Multiple Sockets in Multiple Sites

An option for testers with multiple sockets in multiple sites is the handlers specifying of which sockets contain devices. This is accomplished by a string of numerics after the starting "S"; for example, "S210\r". The digit on the left signifies the test site; the second digit signifies socket 1. The third digit signifies socket 2, the fourth digit signifies socket 3, etc. A 1 means "true"; there is a device in the socket. A 0 means "false"; there is no device in the socket.
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Request for Tester Results
Handler sends: "S111\r" (Site 1 holds devices in sockets 1 and 2) or "S110\r" (Site 1 holds a device in socket 1 but not in socket 2) or "S101\r" (Site 1 holds no device in socket 1, but there is a device in socket 2) or "S211\r" (Site 2 holds devices in sockets 1 and 2) or "S210\r" (Site 2 holds a device in socket 1 but not in socket 2) or "S201\r" (Site 2 holds no device in socket 1, but there is a device in socket 2)
Request for Tester Results

When the handler is ready to read the test result, it sends a request to the tester for the results, and the tester responds. Handler sends to the tester: "E1\r" (Request for result from test site 1) > If the tester is still busy testing, it sends back: "R1B\r" (Site 1 is still busy) or "R2B\r" (Site 2 is still busy) Tester sends: "R10\r" (Requested sites socket 1 result is sort 1; socket 2 holds no device) or "42\r" (Site 4 sort 2) or "43\r" (Site 4 sort 3) or "44\r" (Site 4 sort 4) or "45\r" (Site 4 sort 5) or "46\r" (Site 4 sort 6) or "47\r" (Site 4 sort 7) or "48\r" (Site 4 sort 8) or
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GPIB Test Interface

The GPIB interface is similar to the handler port interface, but it is smarter, with multiple commands. Each socket position is represented in hexadecimal numbering. See "Decimal-Hexadecimal-Binary-ASCII Conversion Table" on page A-23 for details. This interface allows for up to 32 test sockets, with each position represented by "A" or a number in a string of 32 characters separated into 4 groups of 8 bits by commas. Notation
\r \n A [ ]
Meaning
Carriage return Line feed Null value as placeholder Substitute correct value; not literal
The beginning and ending interface commands for both tester-controlled and handler-controlled temperatures are the same. With tester-controlled, the testers setting of test temperature, the testers request for tested temperature, and the handlers supplying of tested temperature are added in the middle.
If the Tester Controls the Testing

Once the handler is powered up, all motors homed, and a job is loaded, the operator can start the handler. The following is the exchange for just one device. (The \r dictates a carriage return.) Handler sends to the tester: H\r (Handler ready to cycle) Tester sends back the location of the device to be tested: R\r (Regular device; handler should get device from tray) or... A\r (handler should get device from Golden Part A pocket) or... B\r (handler should get device from Golden Part B pocket) or... C\r (handler should get device from Golden Part C pocket) Handler sends: S\r (Handler has gotten device from specified location & requests which thermal head to use at what temperature.) Tester specifies which thermal head and what testing temperature (in Celsius) to use: Set_Temp##_R\r (Room-temperature head; temperature is irrelevant) or...
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GPIB Test Interface
If the Handler Controls the Testing
Set_Temp##_C\r (Cold head with temperature) or... Set_Temp##_H\r (Hot head with temperature) Handler sends: Ok\r (Handler has clamped device with specified thermal head and applied specified temperature.) Tester sends Read_Temp?\r (Request for heads temperature.) Handler sends: Temp##.##\r (Handler sends temperature with two decimal places.) At this point, if the thermal heads temperature is outside the range of tolerance, the tester will repeat the request for the heads temperature until it is within the range. Then, if the device passes the test, the tester may ask the handler to test the same device with another thermal head; and the cycle repeats, starting with the testers command Set_Temp##_[C/H/R]. At the end of the testing cycle of one device, or when it has failed a test, the tester gives the sort category: Tester sends: Bin[1-8]. This completes the test cycle for one device.

Again, the following is the exchange for just one device. (The \r dictates a carriage return.) Handler sends to the tester: H\r (Handler ready to cycle) Tester sends back the location of the device to be tested: R\r (Regular device; handler should get device from tray) or... A\r (handler should get device from Golden Part A pocket) or... B\r (handler should get device from Golden Part B pocket) or... C\r (handler should get device from Golden Part C pocket) Handler sends: S\r (Handler has gotten device from specified location & decides which thermal head to use at what temperature.) Tester sends: Bin[1-8]. (Tester has tested the device at the specified temperature and sends the sort result.) This completes the test cycle for one device.
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Exatron uses hexadecimal as an easy way of representing binary. It allows the transmission of an instruction of 2 digits rather than an instruction of 8 digits. The handler decodes the hex instructions into a binary map. Each hex character represents 4 binary digits and 4 sockets. The numbers represent the following outputs. In binary notation, 1 = TRUE and 0 = FALSE. So only the columns, or sockets, with 1s receive devices.
Comparison of Number Systems

Hexadecimal 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 20 30 40 FF FFF9 Binary 0000 0000 0000 0001 0000 0010 0000 0011 0000 0100 0000 0101 0000 0110 0000 0111 0000 1000 0000 1001 0000 1010 0000 1011 0000 1100 0000 1101 0000 1110 0000 1111 0001 0000 0010 0000 0011 0000 0100 0000 1111 1111 Result No device in any socket. Devices in socket 1 only. Devices in socket 2 only. Devices in sockets 1 and 2. Devices in socket 3 only. Devices in sockets 1 and 3. Devices in sockets 2 and 3. Devices in sockets 1 through 3. Devices in socket 4 only. Devices in sockets 1 and 4. Devices in sockets 2 and 4. Devices in sockets 1, 2, and 4. Devices in sockets 3 and 4. Devices in sockets 1, 3, and 4. Devices in sockets 2 through 4. Devices in sockets 1 through 4. Devices in socket 5 only. Devices in socket 6 only. Devices in sockets 5 and 6. Devices in socket 7 only. Devices in sockets 1 through 8. Devices in sockets 1 through 14.
Lets suppose that devices are in sockets 1-4, 7, and 8; but not in sockets 5 and 6. The hex value sent by the handler is CF. The binary code into which the tester would translate this is shown in the bottom row, following. Notice that each bin designated as yes, put here, has a 1 for TRUE.
Socket 8 1 Socket 7 1 Socket 6 0 Socket 5 0 Socket 4 1 Socket 3 1 Socket 2 1 Socket 1 1
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Decimal-Hexadecimal-Binary-ASCII Conversion Table
Decimal-Hexadecimal-Binary-ASCII Conversion Table

Decimal
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Hex
00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20
Binary
0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111 0001 0000 0001 0001 0001 0010 0001 0011 0001 0100 0001 0101 0001 0110 0001 0111 0001 1000 0001 1001 0001 1010 0001 1011 0001 1100 0001 1101 0001 1110 0001 1111 0010 0000
ASCII
Decimal
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
Hex
22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42
Binary
0010 0010 0010 0011 0010 0100 0010 0101 0010 0110 0010 0111 0010 1000 0010 1001 0010 1010 0010 1011 0010 1100 0010 1101 0010 1110 0010 1111 0011 0000 0011 0001 0011 0010 0011 0011 0011 0100 0011 0101 0011 0110 0011 0111 0011 1000 0011 1001 0011 1010 0011 1011 0011 1100 0011 1101 0011 1110 0011 1111 0100 0000 0100 0001 0100 0010
ASCII
" # $ % & ( ) * + , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ A B
Space
66
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Decimal
33 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103
Hex
21 44 45 46 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5D 5E 5F 60 61 62 63 64 65 66 67
Binary
0010 0001 0100 0100 0100 0101 0100 0110 0100 0111 0100 1000 0100 1001 0100 1010 0100 1011 0100 1100 0100 1101 0100 1110 0100 1111 0101 0000 0101 0001 0101 0010 0101 0011 0101 0100 0101 0101 0101 0110 0101 0111 0101 1000 0101 1001 0101 1010 0101 1011 0101 1100 0101 1101 0101 1110 0101 1111 0110 0000 0110 0001 0110 0010 0110 0011 0110 0100 0110 0101 0110 0110 0110 0111
ASCII
! D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ a b c d e f g
Decimal
67 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139
Hex
43 68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D 7E 7F 80 81 82 83 84 85 86 87 88 89 8A 8B
Binary
0100 0011 0110 1000 0110 1001 0110 1010 0110 1011 0110 1100 0110 1101 0110 1110 0110 1111 0111 0000 0111 0001 0111 0010 0111 0011 0111 0100 0111 0101 0111 0110 0111 0111 0111 1000 0111 1001 0111 1010 0111 1011 0111 1100 0111 1101 0111 1110 0111 1111 1000 0000 1000 0001 1000 0010 1000 0011 1000 0100 1000 0101 1000 0110 1000 0111 1000 1000 1000 1001 1000 1010 1000 1011
ASCII
C h i j k l m n o p q r s t u v w x y z { | } ~
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Setting Up HyperTerminal
Configuring a Connection Session
You can set up HyperTerminal in MS Windows as a way of testing communication between the Exatron handlers CPU and a tester. HyperTerminal emulates the communication protocol used by the tester, and displays the results of checking this communication. HyperTerminal uses a serial interface to communicate with the handler. NOTE: You cannot use the Exatron program while you are using HyperTerminal. Before you open HyperTerminal, close the Exatron software. Each message is in uppercase ASCII characters, followed by a carriage return. This ensures that all cables are secure and all communication is taking place.

To set up a new connection session in HyperTerminal: 1. Click the Windows Start button, and select Programs Accessories Communications HyperTerminal.
Figure A-7: Getting to HyperTerminal
> A brief splash screen is displayed. Wait a second for the window to appear.
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> On some systems, an intermediate window may appear. If so, double-click the HYPERTRM.EXE program icon to open the program. If not, go to the next step.
Figure A-8: Opening the HyperTerminal Program
2. In the Connection Description dialog box, type a name for your new connection, and click an icon to identify it. Click OK.
Figure A-9: Naming a New Connection
3. In the Connect To dialog box, click the drop-down arrow by the Connect Using box. Select the COM port you want to use. Click OK.
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Figure A-10: Selecting the Connection
4. In the Properties dialog box, make the selections as shown in Figure A-11. Click OK.
Figure A-11: Selecting the Port Settings
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If your typed commands are not reflected onscreen, you can change the settings to display them. To display commands typed in HyperTerminal: 1. In the main window, click the Properties button.
Figure A-12: Getting to Connection Properties
2. In the Properties dialog box, under the Settings tab, click the ASCII Setup button.
Figure A-13: Getting to ASCII Setup
3. In the ASCII Setup dialog box, check the Echo typed characters locally box to display what you type onscreen. 4. Check Send line ends with line feeds and Append line feeds to incoming line ends to continue displaying what was typed previously. (Thus you can
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Testing Communication Between Handler and Tester
scroll up to view the record, or history, of commands.)
Figure A-14: Displaying Typed Commands Onscreen
5. Click OK. 6. Click OK in the other dialog box. 7. Save your session configurations.
Testing Communication Between Handler and Tester

HyperTerminal displays communication between handler and tester. To test communication between handler and tester: 1. Ensure the tester is turned on and ready. 2. Turn on the handler and get it ready. 3. Open HyperTerminal on the Exatron CPU. 4. Click the Call button to ensure they are connected.
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Figure A-15: Using Call to Connect
5. Press H (always use capitals) on the handler keyboard. > The tester should send an R that is displayed in HyperTerminal. If so, you know that the serial ports between the two machines are connected correctly. 6. Press S on the handler keyboard. > The tester should send a sort number, such as 0, that is displayed in HyperTerminal. If so, you know that the communication is working correctly. 7. To disconnect, click the Disconnect button.
Figure A-16: Disconnecting
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Chapter Overview
This chapter is a quick guide to backing up and restoring the contents of the handler computer, using Acronis True Image software. For more information, see the Acronis Users Guide included on the Acronis software disk. This chapter discusses the following main topics: Topic Setting a Computer to Boot from CD-ROM Creating a Secure Zone on the Hard Disk Backing Up a Hard Disk Copying Archive Files to CDs or DVDs Restoring a Disk or Partition Backup from CD-ROM Restoring a Backup Under Windows Page B-1 B-6 B-15 B-28 B-28 B-40
Setting a Computer to Boot from CD-ROM

Your computer may well be already set up to boot from a CD-ROM if a bootable CD is in the drive at bootup. If not, you can set it to boot from CD-ROM this way. To set the computer to boot from the CD-ROM drive: 1. Turn on the computer and watch carefully during the bootup process for your chance to enter Setup. 2. Press the significant key (usually the <Delete> key) during bootup. > The CMOS Setup Utility is displayed (Figure B-1).
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Figure B-1: CMOS Setup Opened to Main Menu
3. Press the right arrow key to select the Advanced menu (Figure B-2).
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Figure B-2: CMOS Setup Changed to Advanced Menu; Advanced BIOS Features Selected
4. Press the up or down arrow key to select Advanced BIOS Features. 5. Press the Enter key to enter Advanced BIOS Features (Figure B-3).
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Figure B-3: Advanced BIOS Features Screen
6. Press the down arrow key repeatedly until the Second Boot Device line is selected (Figure B-3). 7. Press the Enter key to change its value.
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Figure B-4: Selecting CD-ROM Drive as Boot Device
8. Press the down arrow key repeatedly until the CDROM line has the square selection mark (Figure B-4). 9. Press the Enter key to confirm this selection.
Figure B-5: CD-ROM Drive Selected as Boot Device
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10. Press the F10 key to save your settings.
Figure B-6: Saving Changes
11. Press the Enter key to save and exit (Figure B-6).
Creating a Secure Zone on the Hard Disk

The Acronis Users Guide says, "The Acronis Secure Zone is a special hidden partition for storing archives on the computer system itself. For archive security purposes, ordinary applications cannot access it....Acronis Secure Zone is necessary for using Acronis Startup Recovery Manager and Acronis Snap Restore features." (page 13) This feature is useful if you have the space on your hard disk for the backup. If not, you can back up to portable storage media instead. In that case, skip to the next section, "Backing Up a Hard Disk" on page B-15. To create the Secure Zone: 1. Make sure there is no floppy in the floppy drive. 2. Open Acronis by double-clicking its icon on the desktop.
Figure B-7: Acronis Program Icon
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Figure B-8: Acronis Main Window
The Acronis main window opens.
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Figure B-9: Manage Acronis Secure Zone Button
3. Click the Manage Acronis Secure Zone button at the upper left (Figure B-9).
Figure B-10: Manage Acronis Secure Zone WizardWelcome
4. Click the Next button (Figure B-10).
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Figure B-11: Creating Secure Zone in Unallocated and Free Space
5. Click to place a checkmark and select the disk or partition where you want to create the Secure Zone (Figure B-11). 6. Click the Next button.
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Figure B-12: Specifying Size of Secure Zone
7. Specify the size of the Secure Zone, either by clicking on and dragging the slider, or by typing the size in the Partition size box (Figure B-12). NOTE: It is recommended that you use approximately one-third of the drive size, or 33%, for the Secure Zone. 8. Click the Next button.
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Figure B-13: Activating Acronis Startup Recovery Manager
This allows you to press the F11 key during startup to activate the Recovery Manager.
Figure B-14: Alternate SelectionDo Not Activate Acronis Startup Recovery Manager
9. Click to make your selection (Figure B-11). 10. Click the Next button.
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Figure B-15: Confirming Settings Before Creating Secure Zone
11. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-15. 12. Click the Proceed button.
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Figure B-16: Secure Zone Successfully Created
You can review the parameters of the Secure Zone at any time by clicking the Secure Zone button.
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Figure B-17: Reviewing Properties of the Created Secure Zone
After you have examined the properties, you can click Cancel to exit, or you can make changes as desired.
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Backing Up a Hard Disk

When you make a backup, you can back up selected files and/or folders, or you can back up an entire hard disk or partition. While it is useful to back up selected files on a periodic basis, it is also recommended that you back up the entire hard disk in case of hard disk failure. Exatron makes a full backup of your handlers hard disk before the handler is shipped to you. In case of emergency, you can use the original backup disks to restore the handler PC to its original factory condition.
Figure B-18: Backup Disk Shipped with Handler
To make the backup: 1. On the main window, click the Backup option (Figure B-19).
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Figure B-19: Selecting the Backup Option
Figure B-20: Create Backup WizardWelcome
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2. Click the Next button.
Figure B-21: Selecting Entire Disk or Partition Backup
Figure B-22: Alternate SelectionIndividual Files and Folders Backup
Selecting the entire disk or partition is simpler and ensures no files are omitted, but the backup takes more space. Selecting individual files and folders takes less space, but some files may be inadvertently omitted. 3. Click to make your selection (Figure B-11). 4. Click the Next button.
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Figure B-23: Selecting Partitions to Back Up
5. Click to check all the selections you want. 6. Click the Next button.
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Figure B-24: Explanation of Differences Between Full and Incremental Backups
A full backup contains all the data on the partition or hard disk. It is complete. An incremental backup contains only the data changed since the last backup, whether full or incremental. Therefore, if you have done three incremental backups since the full backup, you need all three incremental backups plus the full backup in order to restore the data. Each incremental is based on the incremental before that. Full backup + incremental + incremental + incremental = Restore
Figure B-25: Restoration Based On Incremental Backups
A differential backup contains all the data changed since the last full backup. Therefore, if you have done three differential backups since the last full backup, you need only the latest differential backup plus the full backup in order to restore the data. Each differential is based only on the full backup, and disregards any differential backups created before it. Full backup + differential ... differential ... differential = Restore
Figure B-26: Restoration Based On Differential Backups
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Figure B-27: Selecting Backup Storage Destination
7. Select the location in which to store the backup and click Next (Figure B-27).
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Figure B-28: Selecting a Full Backup
Figure B-29: Selecting an Incremental Backup
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Figure B-30: Selecting a Differential Backup
8. Select the type of backup you wantfull, incremental, or differential. 9. Click Next.
Figure B-31: Selecting Backup Options
You may want to set the options manually. Among these options are password protection, compression level, and specifying the size of the backup files for transference to various portable media (Archive splitting, Figure B-32).
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Figure B-32: Archive SplittingAutomatic
10. Click any of the options in the left box to examine and set the options. Archive splitting can be set to automatic or fixed size. NOTE: It is strongly recommended that you use the Fixed size option and back up to another hard drive first, splitting archive files small enough to fit at least two archive files on each anticipated CD or DVD; then afterward copy the backup files to CDs or DVDs. See "Copying Archive Files to CDs or DVDs" on page B-28. Automatic size is for backing up directly to a series of CDs or DVDs. When each disk is full, you will be prompted for another one. This method is not recommended, as the backup is unreliable. Fixed size is good if you are backing up to a hard drive now, with the intention of copying the backup to a specific set of portable media afterward.
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Figure B-33: Archive SplittingFixed Size
Figure B-34: Drop-Down List of Fixed Sizes
11. It is recommended that you select a size small enough to get at least two of the archive files (the first and last files) on one media. > For example, if you will be copying the files to DVDs, then select the 650 or 700 MB size, to get multiple files on one disk. But if you will be copying the files to CDs, then select the 100 MB size, to get multiple files on one disk. 12. Select the desired options and click Next.
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Figure B-35: Adding Optional Archive Comments
13. Type any descriptions of the contents of the disk or folders. 14. Click Next.
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Figure B-36: Confirming Settings Before Creating Backup
15. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-36. 16. Click the Proceed button. During the backup, the progress bar shows how the backup is progressing (Figure B-37).
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Figure B-37: Progress Bar Displayed While Backup Is Created
Figure B-38: Successful Completion
Figure B-39: Archive Files Created
After the backup is complete, you can see the archive file(s) on your storage media.
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Copying Archive Files to CDs or DVDs

If you have backed up to a second hard drive using fixed file size and archive splitting as recommended, you should next copy the archive files to CD or DVD. Copy the first and last archive files to the first CD or DVD, so the program will know how many archive files to request. Then copy the other archive files to other CDs or DVDs if necessary, so that all the archive files are included.
Restoring a Disk or Partition Backup from CD-ROM

If you have backed up an entire disk or partition and Windows cannot load, you will need to boot from the bootable Acronis CD-ROM. Do it this way. To restore the backup: 1. Make sure there is no floppy in the floppy drive. 2. Insert the Acronis boot disk in the CD-ROM drive. The Acronis splash screen is displayed, followed by the main window (Figure B-40, Figure B-41).
Figure B-40: Acronis Boot Disk Inserted in Drive (Left); Acronis Splash Screen (Right)
3. Double-click the Restore Image selection (Figure B-41).
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Figure B-41: Acronis Main Screen with Restore Option
4. Remove the Acronis boot disk from the CD-ROM drive, and insert the CD-ROM containing the last file in the backup series of CD-ROM disks. CAUTION: Be sure to insert the last recovery disk first. If you insert any CDROM out of order, or dont start with the last one, you will see an error message (Figure B-42). Insert the correct CD and continue.
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Figure B-42: Error Messages Due to Inserting Wrong Backup Disk
Figure B-43: Restore Image WizardWelcome
The Restore Image Wizard displays the Welcome screen. 5. Click the Next button.
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Figure B-44: Selecting Archive File for Restoration
6. Double-click the CD-ROM drive to display its contents (Figure B-44). 7. Click the Next button.
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Figure B-45: Option to Verify Archive
If you are overwriting the contents of the hard disk with the recovery, you may want to verify the archive before overwriting. 8. Select whether or not to verify before restoring. 9. Click the Next button.
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Figure B-46: Selecting Partition or Disk to Restore
10. Check the disk partition you want to restore. 11. Click the Next button.
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Figure B-47: Option to Resize Partitions
You have the option to resize partitions. Doing so may be useful if you are migrating to a larger hard disk, 12. Select whether or not to resize partitions. 13. Click the Next button.
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Figure B-48: Resizing Partitions
14. Click to select the disk location. 15. Slide to resize each partition. 16. Click the Next button.
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Figure B-49: Deleting Partitions on Destination HD
17. Click Yes to delete all the partitions on the destination drive. NOTE: If you click No, the restoration process stops. 18. Click the Next button.
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Figure B-50: Option to Restore Additional Partition
You are given the option to restore an additional partition. 19. Make your selection and click Next.
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Figure B-51: Confirming Settings Before Restoring Partition
20. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-51. 21. Click Proceed. As the recovery progresses, you are asked to insert the backup disks in order. 22. Insert each requested disk when prompted (Figure B-52).
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Figure B-52: Prompts to Insert Series of Recovery Disks
The restoration is completed.
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Restoring a Backup Under Windows

If Windows is running normally, you should use Acronis True Image under Windows, because it provides more functionality. Do it this way. To restore a backup under Windows: 1. Open Acronis by double-clicking its icon on the desktop (Figure B-7). 2. Click the Recovery selection (Figure B-54).
Figure B-54: Selecting the Recovery Option
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Figure B-55: Restore Data WizardWelcome
3. Click Next.
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Figure B-56: Selecting Location of Archive File
4. Select the location where your archive file is stored and the name of the archive file. 5. Click Next.
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Figure B-57: Selecting Original or New Location for Restoration
Figure B-57 asks for the location where you want the files restored: the same location they were in originally, or a new location. 6. Select original or new location. 7. Click Next.
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Figure B-58: Selecting Restoration Destination
If you selected a new destination, Figure B-58 asks you to specify the destination of the restoration. 8. Select the destination for the restoration. 9. Click Next.
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Figure B-59: Selecting Archive Files to Be Restored
10. Select the archive files to be restored. 11. Click Next.
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Figure B-60: Selecting Restoration Options
12. Select default or manual options for restoration. 13. Click Next.
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Figure B-61: Selecting Restoration Options Manually
If you selected manual options, a list of available options is showed at the left of Figure B-61. 14. Select any options for restoration. 15. Click Next.
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Figure B-62: Selecting Whether to Overwrite Existing Files
16. Select whether to overwrite existing files. 17. Click Next.
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Figure B-63: Confirming Settings Before Restoring Data
18. Verify the proposed operations and settings. > If you want to make any changes, click the Back button one or more times until you reach the settings to be changed, and make any desired changes. Then click Next until you get back to the window shown in Figure B-63. 19. Click Proceed.
01/2011
B-49
Figure B-64: Progress Bar Displayed While Data Is Restored
Figure B-66: Restored Files
After the restoration is complete, you can see the restored files in the selected location.
B-50
01/2011
Index
A
air blow. See blow-off air filter 1-5, 2-16, 8-28 air flow 8-23, 8-27 air flow control adjustment knob 3-24 air pressure 2-15, 8-22 see also blow-off fittings 1-5, 8-65 recommended range 8-27, 8-28 air regulator 8-18, 8-65 adjusting pressure 8-22 auxiliary 2-15, 8-22 locking in OFF position 1-3 main 2-15, 8-22 replacing 8-19 air supply 1-2, 1-5, 8-18, 8-27, 8-65 air valves 2-17, 8-23 alodine, conductive gold 2-23 archive files, in backup 12-23, 12-24 ASCII values 11-23 Auto Run pausing 5-1, 5-6 restarting 5-1, 5-6 taper settings 5-5 tracking device counts 2-16, 5-8 Auto Run window 6-4 automatic air shut-off valve 3-5 auxiliary pusher regulator. See air regulator, auxiliary axis, Z 1-24, 4-26 bowl feeder continued dead nest 4-24, 7-1, 7-11 discharge 7-1, 7-13 inline track 7-1, 7-12 overview 7-1 quick-dump of devices 7-8 sensors 7-5 buckets 2-7 buttons CPU 3-5, 3-6 EMO (emergency stop) 1-2, 2-9, 2-21, 3-5, 3-6, 5-1, 8-2 HALT and RUN 2-9, 5-1 handler software Diagnostic 4-2 Main window 3-26 OK 3-31 Save Parameters 3-31 override, taper 4-17 tester software 6-2, 6-6, 6-10 Windows Start 3-5
C
calibration 4-19 pickup heads 4-26 pickup wheel offset 4-25 sort wheel offset 4-26 taper seal head 3-18 software 4-34 vacuum generator 8-36 camera. See image sensor carriers 2-13 cautions and warnings adjusting blow-off screw 2-16 back up hard drive regularly 8-2 changing motor speeds may cause damage 4-11 connect power to grounded outlet 1-4 dont bump bowl feeder attachments 7-8 dont change factory-set job file 3-30, 4-2 dont change IP addresses 8-50 dont interfere with moving parts 1-1 dont lubricate lead screws 8-2 dont lubricate solenoids 8-44 dont over-adjust blow-off screw on vacuum generator 8-30 dont over-adjust blow-off screw on vacuum switch 8-30 continued on next column
B
bearings 8-3 binary values 11-23 bins 1-22 blow-off 1-22, 2-14, 2-15 adjustment screw 2-16, 8-29, 8-65 dead nest 4-24 delay 4-24 operation 2-15, 8-65 bowl feeder air jets 7-5, 7-6 alignment block 7-14 changeover kit 3-3, 7-8 changeover kit storage plate 7-7 changeover procedure 7-7 continued on next column
01/2011
Index-1
cautions and warnings continued dont overtighten screws on bowl feeder changeover kit 7-13 dont remove safety covers during operation 1-2 dont touch adhesive tape to carrier tape 3-18 dont touch hot taper seal heads 3-22 dont unplug air hose when air regulator on 1-2 dont use cleaners on bearings or lead screws 8-2, 8-4 dont use handler without approved air regulator 1-2 home all motors before starting 1-1 insert last recovery disk first 12-29 keep away from moving parts 1-1 lock air regulator in OFF position before repairing handler 1-3 lock wheels and level feet 1-6 maintain file backups on external media 8-61 maximum air pressure 50 PSI from vacuum pump 8-28 power off system before maintenance 8-2 prevent excess moisture in air regulator and air valves 8-18 preview movement to avoid collisions 4-10 replace dirty vacuum filter 2-16, 8-28 servicing of laser should be done by LSO 1-2, 8-50 CE Marking upgrade options 2-22 changeover kits bowl feeder 3-3, 7-7, 7-8 taper 3-3, 3-9, 3-10 communication between handler software and hardware 4-4, 4-14 tester 11-1, 11-29 computer boards 8000-D14 2-12 accessing 8-44 PCM-6896 2-12 PET-C06 2-12 computers backing up hard disk 12-15 opening 8-44 restoring hard disk 12-28, 12-40 shutting down 2-8, 3-5 switching between 6-1 conductive gold alodine 2-23 contracts preventive maintenance 1-12 service 1-9 covers and doors 1-2 CPU button 3-5, 3-6 CPU. See computers
D
decimal values 11-23 delays before air blow-off 4-24 before vacuum off 4-36 seal head 4-36 vacuum 4-24 devices multiple-value testing 6-8 single-value testing 6-4 sizes 3-3, 3-10, 4-15, 4-16, 7-8 totals 5-6, 5-8 Diagnostics windows. See under software, Exatron, windows disconnect switch 1-4, 2-8, 2-9, 2-23, 3-4, 3-6 documentation typography significance 1-22 version number significance 1-21 doors 1-2 drive gear (taper) 2-20
E
earthquake safety 1-6, 3-1 electrical capability 1-4 EMO (emergency stop) button 8-2 starting 3-5 stopping 1-2, 2-9, 3-6, 5-1 taper 2-21 end-of-life disposal 1-21
F
feet, leveling 2-8, 3-1 files archive 12-23, 12-24 backing up 8-2 job see job files software upgrades 8-61 system 8-61 Fine Tune window 4-19 fuses 2-12
G
gap offset 4-37, 4-38, 5-5 GPIB test interface 11-20
Index-2
01/2011
Index
H
HALT button 2-9, 5-1 handler cleaning 8-3 end-of-life disposal 1-21 installing 1-6, 3-1 opening computer 8-44 operation overview 2-2 powering up 3-4 remote control 8-59 requirements electrical 1-4 environmental 1-4 Internet access 1-5 pressurized air 1-5 servicing 8-1 shutting down 3-5 troubleshooting 8-64 handler parts see also individual part names, test sites air filter 2-16, 8-28 air pressure fittings 1-5, 8-65 air regulator auxiliary 2-15, 8-22 main 2-15, 8-22 automatic air shut-off valve 3-5 bearings 8-3 brand names Baco disconnect switch 1-4, 2-9, 2-23, 3-4, 3-6 Cool Muscle motors 8-7, 8-15 Kerk lead screws 8-4 Omron fiberoptic sensor controllers 8-48 Rodix feeder cube 7-2 SMC air regulators 8-19, 8-22 SMC vacuum generators 8-25 SMC vacuum switches 8-25 Thomson bearing shafts 8-4 Thomson bearings 8-4 buckets 2-7 buttons HALT and RUN 2-9, 5-1 override taper 2-22 carriers 2-13 chains 2-6, 9-2 computer boards 2-12 connectors 24-pin D 11-4, 11-5 covers and doors 1-2 CPU button 3-5, 3-6 diagram 2-3 continued on next column
handler parts continued disconnect switch 1-4, 2-9, 2-23, 3-4 EMO (emergency stop) button 1-2, 2-9, 3-5, 3-6, 5-1, 8-2 feet, leveling 2-8, 3-1 fuses 2-12 HALT and RUN buttons 2-9, 5-1 hub 2-12, 8-17 interlocks 1-2 lead screws 2-6, 8-5 line filter 2-24 main disconnect switch 2-8, 2-9, 2-23, 3-4 manifold 2-17 motor serial cables 8-17 motors 2-4, 4-36 photos 2-4 to 2-24 pickup heads 2-5 ports 4-6 power supplies 2-10 power switch 3-5, 3-6 sensors 2-16, 8-36 see also sensors solenoids 4-4 suction cups 2-14, 8-3 vacuum generators see vacuum generators vacuum pump 8-30, 8-31 wiring 8-17 handler port simulator 11-6 hardware. See handler parts heat seal head (taper) cleaning 8-49 enabling or disabling 4-41 intermittent tape contact 2-19 setting temperature 3-25 stopping 2-21 heater controller display (taper) 2-21, 3-25 heater fuse (taper) 2-21 hex values 11-23 home positions 4-20, 4-21, 4-25, 4-26 hub 2-12, 8-17 HyperTerminal 11-25
I
image sensor inspection files 4-15 image sensor (taper) 2-18, 2-19 inspection files 4-15 installation 1-6 interface card 8-7
01/2011
Index-3
interfaces GPIB 11-2, 11-20 RS-232. See RS-232 test interface RS-485 11-2 TTL 11-2, 11-4 interlocks 1-2 IP addresses 8-50, 8-56
motors 2-4 homing 4-11, 4-12 master vs. slave 8-8 programming 8-15 replacing 8-12 taper 4-36 turning on and off 4-10, 4-11, 4-12 Multiple-Value mode 2-4, 2-7, 6-2, 6-8
J
job files copying 3-28, 4-2 definition 3-27 factory preset 3-3 for various devices 4-2 opening 3-29, 5-2 saving 3-31 verifying 3-27 jobs, running 5-1, 12-1
N
network cards 8-7 networking Internet access 1-5 IP addresses 8-50 LAN connections 8-50 remote handler control 8-59
O
offset gap (taper) 4-37, 4-38, 5-5 output sort wheel 4-20, 4-26 pickup wheel 4-21, 4-25 output sort wheel carriers 2-13 offset 4-20, 4-26 rotary motor 2-4 override button lights (taper) 2-21 1-3
L
LAN connections 8-50 laser 8-50 lead screws 2-6, 8-5 LED checker 11-6 leveling feet 2-8, 3-1 line filter 2-24 lock-out/tag-out (LOTO) procedures lubrication 8-3
P
passwords 3-5, 3-30, 3-31, 4-2 PC. See computers PCBs. See computer boards peel tester (taper) 3-14 photos, handler parts 2-4 to 2-24 pick height. See Z-pick pickup heads 2-5 assembly 2-6 blow-off 8-29 home position 4-26 looseness 8-65 positions 8-65 suction cups 4-27, 8-3, 8-64 pickup wheel offset 4-21, 4-25 pushers 2-4 rotary motor 2-4 pin designations 11-5
M
machine. See handler main disconnect switch 2-8, 2-9, 2-23, 3-4 maintenance. See preventive maintenance, tasks manifold 2-17 manual, users typography significance 1-22 version number significance 1-21 messages between handler and tester 11-1 resetting motors 4-19 modes Multiple-Value 2-4, 2-7, 6-2, 6-8 Single-Value 2-4, 2-7, 6-2, 6-4 motor controllers 8-7 Motor window 4-10
Index-4
01/2011
Index
ports 4-6, 11-2, 11-3, 11-25 TTL Handler Port 11-4, 11-6 positions calibrating 4-19 to 4-27 Z-drop 4-36 Z-pick vs. Z-drop 4-26, 4-27 power supplies 2-10 power switch 3-5, 3-6 pressure roller block (taper) 2-20 pressure seal heads (taper) continuous tape contact 2-19 enabling or disabling 4-41 maintenance 8-49 preventive maintenance 8-1 preventive maintenance contract 1-12 put height. See Z-drop
R
remote handler control 8-59 RS-232 test interface 11-8 RUN button 2-9, 5-1
S
safety and security see also cautions and warnings CE Marking upgrade options 2-22 earthquake safety 1-6, 3-1 handler covers and interlocks 1-2 hard disk backup 12-15 lock-out/tag-out procedures 1-3 training responsibilities 1-1 seal head (taper) 2-19 adjusting 3-18 adjusting lateral position 3-21 adjusting pressure 3-23 cleaning 8-49 delay 4-36 disabling 4-41 seismic safety 1-6, 3-1 Sensor/Solenoid Check window 4-14 sensors 2-14 bowl feeder 7-5 bucket 2-8 checking 4-4, 4-14 cleaning optics 8-49 controllers 8-48
sensors continued taper Gap 2-19, 4-18, 4-38, 5-5 lights 2-21 vacuum generator 2-16, 8-36, 8-64 service contract 1-9 Single-Value mode 2-4, 2-7, 6-2, 6-4 smart buckets 2-7 software Acronis True Image 12-1 backup 12-15 emergency recovery 12-28 normal recovery 12-40 Secure Zone 12-6 Exatron handler Auto Run 5-2 Diagnostics 4-2 Fine Tune 4-19 Motor 4-10 Sensor/Solenoid Check 4-14 Taper 4-34 USB Sensor/Solenoid Check 4-4 Main 3-26 HyperTerminal 11-25 MS Windows, shutting down 3-5 tester Multiple-Value mode 6-8 Single-Value mode 6-4 WebEx 8-59 solenoids 4-4, 4-14, 8-44 sort buckets 2-7 sorts 1-24 suction cups 2-14, 8-64, 9-1 positions Z-drop 4-27 Z-pick 4-26, 4-27 support services 1-7, 1-8, 1-15, 1-21
T
takeup arm (taper) 3-13 takeup reel (taper) 2-18, 3-7 tape carrier 3-12, 3-16 direction of movement 2-18 gap offset 4-37, 4-38, 5-5 homing 4-38, 5-5 initializing 4-38, 5-5 leader 3-12, 4-38, 5-5 passed devices in job 5-6 sealing 3-14, 3-16 continued on next column
continued on next column
01/2011
Index-5
tape continued threading through assembly 3-14 trailer 4-39, 5-6 taper alignment knob 2-18 calibrating software 4-34 changeover kit 3-3, 3-9, 3-10 changing seal head blade 3-19 changing tape track 3-9 disabling 4-23 drive gear 2-20 EMO (emergency stop) button 2-21 facilities requirements 1-4, 1-5 guide block 3-15, 3-16, 3-17 heater controller display 2-21, 3-25 heater fuse 2-21 image sensor 2-18 Model 201 2-18, 3-7 Model 202 2-18, 3-7 motor 4-36 override button lights 2-21 override buttons 2-22, 4-17 peel tester 3-14 pressure roller block 2-20 sensor lights 2-21 sensors Gap 2-19, 4-18 takeup arm 3-13, 3-14 takeup reel 2-18, 3-7 tape track 2-18, 3-7 track width locking knob 2-21 Taper window 4-34 tasks adjusting air flow 3-24, 8-24 adjusting air pressure 8-22 adjusting blow-off 8-29 backing up PC hard disk 12-15 bowl feeder emptying of devices 7-8 installing changeover kit 7-13 removing changeover kit 7-11 calibration positions 3-31 vacuum generator 8-39 changing password 3-31 checking air filter 8-28 checking air regulator moisture/dirt trap 8-18 checking air regulator shutoff valve 8-21 checking air supply from house generator 8-18 checking motor serial cables 8-17 checking or replacing air filter 8-19 checking vacuum generator adjustment 8-36 continued on next column
tasks continued cleaning handler 8-3 cleaning suction cups 8-3 cleaning vacuum assembly 8-32 copying job file 3-28 creating backup Secure Zone on hard disk 12-6 displaying commands typed in HyperTerminal 11-28, 11-29 entering Diagnostics 4-2 installing Exatron software 8-61 lubricating bearing shafts 8-4 opening computer 8-45 opening job file 3-29 powering up system 3-4 programming motor 8-15 reformatting job file 8-63 replacing motors 8-12 restoring backup under Windows 12-40 restoring backup without Windows 12-28 setting LAN connection 8-51 setting PC to boot from CD 12-1 setting up HyperTerminal 11-25 shutting down system 3-5 starting Auto Run 5-2 taper adjusting seal heads lateral position 3-21 adjusting seal heads pressure 3-23 adjusting seal heads speed 3-24 calibrating software 4-34 changing seal head blade 3-19 changing tape track 3-9, 3-10 loading carrier tape 3-12 loading sealing tape 3-14 maintenance 8-49 mounting takeup reel 3-8 setting temperature for heat seal 3-25 turning off temperature for heat seal 3-26 testing network communication with peripherals 8-56 tightening lead screws 8-5 viewing vacuum generator settings 8-42 TCP/IP interface 11-3 temperatures, setting (taper) 3-25 test interfaces. See GPIB test interface, RS-232 test interface, TCP/IP interface, TTL (TransistorTransistor Logic) test interface test sites checking communication 11-25 instructions from vendor 3-2 manifold 2-17 multiple 11-9
Index-6
01/2011
Index
tester Multiple-Value mode 6-2, 6-8 Single-Value mode 6-2, 6-4 testing interfaces 11-1 modes 2-4, 2-7, 6-4, 6-8 Testing Multiple Values window 6-8 track width locking knob (taper) 2-21 trays 2-2 troubleshooting devices not picked up 8-27, 8-64 hard disk wont boot 12-15, 12-28 motors slow 8-64 TTL (Transistor-Transistor Logic) test interface 11-4 TTL Handler Port 11-4, 11-6 typography significance 1-22
windows. See under software wiring 8-17
Z
Z see also pickup heads axis 1-24, 4-26 calibration for bowl feeder 7-14 for taper 4-34 chain 2-6, 9-2 Z-drop 4-26 Z-get. See Z-pick Z-pick 4-26, 8-64 Z-put. See Z-drop
U
USB Sensor/Solenoid Check window 4-4
V
vacuum 2-14 dead nest 4-24 delay 4-24 sensor 8-64 vacuum generators 2-15, 2-16 blow-off adjustment 8-30 blow-off location 8-27 calibrating 8-39 checking 8-36, 8-42 cleaning 8-32 override buttons 8-39 ports 8-26 suggested settings 8-38 troubleshooting 8-27 vacuum pump 8-30, 8-31 vacuum switches see also vacuum generators blow-off adjustment 8-30 blow-off location 8-27 how different from vacuum generators vibrations. See bowl feeder or feet
8-25
W
warnings. See cautions and warnings warranty agreement 1-5, 1-6, 1-7, 1-8, 8-2 WebEx 8-59 Windows, shutting down 3-5
01/2011
Index-7
Index-8
01/2011

Model 7000 Manual

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Pick and Place Handler Model 7000-BPR User Manual

Version 1.0 January 10, 2011

Chapter 2: System Description

-- continued on next page --

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 2: System Description continued

Chapter 3: Hardware and Software Setup

Copyright Exatron, 2011

Chapter 3: Hardware and Software Setup continued

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 4: Diagnostics continued

Chapter 5: Auto Run

Chapter 6: Resistor Tester

Copyright Exatron, 2011

Chapter 6: Resistor Tester continued

Chapter 7: Bowl Feeder

Chapter 8: Servicing and Troubleshooting

-- continued on next page --

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 8: Servicing and Troubleshooting continued

Chapter 9: Parts List

Copyright Exatron, 2011

Chapter 9: Parts List continued

Chapter 10: Prints

Appendix A: Test Interfaces

Copyright Exatron, 2011

Model 7000-BPR Manual

Appendix A: Test Interfaces continued

Appendix B: System Backup and Recovery

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Copyright Exatron, 2011

Chapter 1: Safety, Support and Options

Exatron Safety Warnings

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 1: Safety, Support and Options

Figure 1-1: EMO (Emergency Stop) Button

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 1: Safety, Support and Options

Copyright Exatron, 2011

Copyright Exatron, 2011

Model 7000-BPR Manual

Chapter 1: Safety, Support and Options

Uncrating the Handler

Mounting the Handler

Original Customer PO# : Original Ship date#:____